Modification of surface finish produced by hard turning using superfinishing and burnishing operations

In this study the surface finish produced by hard turning of a 41Cr4 low-alloy steel quenched to about 60 HRC hardness, using mixed Al₂O₃-TiC ceramic inserts, was subsequently modified by superfinishing and multipass burnishing operations. In the case of hard turning surfaces were produced by conventional and Wiper cutting tool inserts. The main goal of this study was to examine how additional abrasive and non-removal technological operations change 2D and 3D roughness parameters and enhance service properties of the machined surfaces. It was documented that both superfinishing and burnishing operations allow to obtain smoother surfaces with lower surface roughness and better bearing characteristics.     

Effects of honing treatment on AIP-TiN and TiAlN coated end-mill for high speed machining

The objective of this work is to compare the tool performance of TiN and TiAlN coated carbides end-mills deposited by an arc ion plating (AIP) method, using honing treatment to polish the cutting edge surface sleekly. The curve of surface roughness versus honing time showed a rapid improvement initially and thereafter became steady, manifesting a saturation effect. The optimal honing time related to surface roughness was determined to be approximately 20 s. As the surface roughness increased, the critical loads reduced. At an average surface roughness (R_a) of 0.028 (m, the highest critical loads of TiN and TiAlN coating layers were 98 and 114 N, respectively. Tool performances of uncoated and coated tools were conducted under high speed machining (HSM) of AISI D2 cold-worked die steel (62 HRC). Consequently, the TiAlN coated end-mill using honing treatment showed excellent tool life under HSM conditions.     

Wavelet and fractal approach to surface roughness characterization after finish turning of different workpiece materials

In this paper, the surface profiles generated in longitudinal turning operations were characterized using continuous wavelet transform (CWT) and normalized fractal dimension D_n. In the comparative analysis, some characteristic roughness profiles after the turning of different workpiece materials, such as C45 medium carbon steel, nodular cast iron and hardened (55 HRC) high-strength alloy steel were selected. For wavelet characterization, both Morlet and ‘Mexican hat’ analyzing wavelets, which allow the assessment of extrema and frequency distribution, were utilized. The results of the CWT as a function of profile and momentary wavelet length are presented. It is concluded that CWT can be useful for the analysis of the roughness profiles generated by cutting processes. Moreover, the wavelet transform together with fractal dimension can be capable of the detection of local self-similarity in the surface profile.     

Erosion testing and surface preparation using abrasive water-jetting

Erosion testing and surface preparation are studied using a 3-axis Computer Numerical Control (CNC) abrasive water jetting (AWJ) apparatus. The effects of erosion time t, impingement angle α and pressure p on the erosion rate E, average surface roughness R _a, and surface hardness Rockwell C Hardness (HRC) were investigated in detail. Compared with conventional grit blasting, AWJ can reduce grit embedment in the target material due to the action of the high-pressure water. AWJ also has the advantage of generating a higher average surface roughness R _a over water jetting (WJ) due to the action of abrasive particles. In addition, AWJ increases the surface hardness HRC of the substrate material. The obtained higher degree of average surface roughness is helpful for improving the bonding strength between the coating and the substrate material. The erosion testing and the surface preparation are numerically controlled by a 3-axis CNC system; therefore precise and detailed results for various operating parameters can be obtained.     

Experimental study on machinability improvement of hardened tool steel using two dimensional vibration-assisted micro-end-milling

High strength, low thermal conductivity and high work hardening tendency of tool steel are the main factors that make its machinability difficult. In this paper, two dimensional vibration-assisted micro-end-milling (2-D VAMEM) is applied to machine the hardened tool steel (HRC 55 and HRC 58) in order to improve its machinability. The experiments are carried out to study the effects of vibration parameters on the surface roughness and the tool wear. It is found that 2-D VAMEM can improve the surface roughness and reduce the tool wear compared to traditional micro-end-milling, and larger amplitude and higher frequency are useful for the surface roughness improvement and the tool wear reduction. Therefore, 2-D VAMEM is an effective method to milling of hardened tool steel and can be applied in the manufacture of moulds and dies with improved machining efficiency, surface quality and tool life.     

Experimental study on ultrasonic elliptical vibration cutting of hardened steel using PCD tools

Diamond tools cannot usually be applied for machining hardened steels while applying conventional cutting technique. As an alternative, ultrasonic elliptical vibration cutting (UEVC) technique was successfully applied for obtaining mirror surface on such steels using single crystal diamond (SCD) tools. In order to reduce production cost without compromising mirror surface quality, polycrystalline diamond (PCD) tools may be tested against highly expensive SCD tools. However, study on machining of hardened steel using PCD tools applying the UEVC technique has not yet been reported. The current research presents an experimental study on UEVC of hardened stainless steel (a typical Stavax, hardness 49 HRC) using the PCD tools. Face turning experiments were carried out to investigate the effects of three machining parameters: nominal depth of cut, feed rate, and nominal cutting speed on output performances such as cutting force, tool flank wear, surface roughness, and chip formation. Experimental results show that nominal cutting speed has very strong influence on the output performances, compared to the other two parameters. The surface roughness improves with a decrease in cutting speed. A mirror-like surface of approximately 804 mm² with a roughness value R_a of 11 nm was achieved at a lower cutting speed. Theoretical explanations have been given to support the results drawn from the UEVC experiments. It can be concluded that, while applying the UEVC technique, the inexpensive PCD tools instead of the SCD tools can be effectively applied to obtain optical surface for producing precise molds from the hardened steel.     

Wear model in turning of hardened steel with PCBN tool

In this study a mathematical–computational model of tool wear of PCBN (polycrystalline cubic boron nitride) was developed in turning of quenched and tempered AISI D6 steel (57 HRC) using experimental planning and statistic techniques. On the experimental trials many parameters are important such as: surface roughness, cutting force and tool wear. These parameters were evaluated according to their statistical significance using Statistica^® and Matlab^® softwares. Through a multiple-regression analysis, it was possible to establish a mathematical model for estimating tool wear as a function of the cutting parameters. This model enhanced estimation of the ideal cutting conditions for turning hardened steel, i.e., those that generate minimum damage on the PCBN tool without compromising productivity.     

Surface layer characteristics due to slide diamond burnishing with a cylindrical-ended tool

The article presents an unconventional method of finishing shafts - slide burnishing with a cylindrical-ended tool whose axis is perpendicular to that of the worked shaft. The contact area of the tool with the workpiece and the tool force necessary for burnishing 42CrMo4 alloy steel shafts were calculated. The effect of burnishing parameters on the surface stereometric structure, the surface layer hardening and the distribution of final stresses was examined. Compared with grinding, a considerable improvement in surface condition indicators was found and it was possible to achieve a surface roughness, Sa of 0.05-0.18 μm. Surface microhardness increased by up to 29% and compressive stresses of up to a 400 MPa of the absolute value occurred in the surface layer. The effect of burnishing parameters on surface roughness, Sa and oscillatory bending strength were examined and the relevant mathematical models - multinominals of the second order that also allow for the interaction of input factors were obtained. Fatigue strength improved (compared to that of the ground workpieces) by 18%. It was found that those effects can be achieved without a lot of technological effort.     

Hard machining of hardened bearing steel using cubic boron nitride tool

In many cases, hard machining remains an economic alternative for bearing parts fabrication using hardened steels. The aim of this experimental investigation is to establish the behaviour of a CBN tool during hard turning of 100Cr6-tempered steel. Initially, a series of long-duration wear tests is planned to elucidate the cutting speed effects on the various tool wear forms. Then, a second set of experiments is devoted to the study of surface roughness, cutting forces and temperature changes in both the chip and the workpiece. The results show that CBN tool offers a good wear resistance despite the aggressiveness of the 100Cr6 at 60HRC. The major part of the heat generated during machining is mainly dissipated through the chip. Beyond 280 m/min, the machining system becomes unstable and produces significant sparks and vibrations after only a few minutes of work. The optimal productivity of machined chip was recorded at a speed of 120 m/min for an acceptable tool flank wear below 0.4 mm. Beyond this limiting speed, roughness (R_a) is stabilized because of a reduction in the cutting forces at high speeds leading to a stability of the machining system. The controlling parameter over roughness, in such hard turning cases, remains tool advance although ideal models do not describe this effect rationally. Surface quality obtained with CBN tool significantly compared with that of grinding despite an increase in the advance by a factor of 2.5. A relationship between flank wear (VB) and roughness (R_a) is deduced from parametric analysis based on extensive experimental data.     

Prediction and control of surface roughness in CNC lathe using artificial neural network

In this study, a neural network approach is presented for the prediction and control of surface roughness in a computer numerically controlled (CNC) lathe. Experiments have been performed on the CNC lathe to obtain the data used for the training and testing of a neural network. The parameters used in the experiment were reduced to three cutting parameters which consisted of depth of cutting, cutting speed, and feed rate. Each of the other parameters such as tool nose radius, tool overhang, approach angle, workpiece length, workpiece diameter and workpiece material was taken as constant. A feed forward multi-layered neural network was developed and the network model was trained using the scaled conjugate gradient algorithm (SCGA), which is a type of back-propagation. The adaptive learning rate was used. Therefore, the learning rate was not selected before training and it was adjusted during training to minimize training time. The number of iterations was 8000 and no smoothing factor was used. R_a, R_z and R_max were modeled and were evaluated individually. One hidden layer was used for all models while the numbers of neurons in the hidden layer of the R_a model were five and the numbers of neurons in the hidden layers of the R_z and R_max models were ten. The results of the neural network approach were compared with actual values. In addition, inasmuch as the control of surface roughness is proposed, a control algorithm was developed in the present investigation. The desired surface roughness was entered into the control system as a reference value and the controller determined the cutting parameters for these surface roughness values. A new surface roughness value was determined by sending the cutting parameters to the observer (ANN block). The obtained surface roughness was fed back to the comparison unit and was compared with the reference value and the difference surface roughness was then sent to the controller. The iteration was continued until the difference was reduced to a certain value of surface roughness which could be permitted for machining accuracy. When the surface roughness reached the permitted value, these cutting parameters were sent to the CNC turning system as input values. In conclusion, both the surface roughness values corresponding to the cutting parameters and suitable cutting parameters for a certain surface roughness can be determined prior to a machining operation using the ANN and control algorithm.     

安全阀阀座与阀瓣研磨修复工艺实验研究

目的为满足安全阀阀座与阀瓣配合面密封要求,提高安全阀密封面磨削修复质量和效率,阀座和阀瓣表面粗糙度Ra≤0.1μm。方法在正交实验的基础上,采用Al_2O_3砂纸、白刚玉研磨膏为磨削介质,研究了磨粒细度、磨削时间、磨削转速、磨削压力对密封表面粗糙度和磨削量的影响,使用粗糙度测量仪、千分尺、电子显微镜对阀座和阀瓣的表面粗糙度、磨削量、表面形貌进行测量分析。以磨削量和表面粗糙度为评价指标,得到最佳工艺参数,并通过多组重复性实验验证实验结果的可靠性。结果在最佳磨削工艺参数下,砂纸研磨阀座和阀瓣的磨削量为0.023 mm,表面粗糙度为0.135μm,研磨膏抛光阀座和阀瓣的表面粗糙度为0.073μm。结论砂纸研磨最佳工艺参数:研磨压力80 N,研磨转速80 r/min,研磨时间10 min,砂纸细度1000目。研磨膏抛光最佳工艺参数:抛光压力30 N,抛光转速100 r/min,抛光时间10 min。采用砂纸、研磨膏磨削修复工艺,可以提高磨削量,降低表面粗糙度,提高了安全阀磨削后的密封性能。     

Influence of the stress,strain, and temperature on the surface roughness of an AlSl 52100 steel due to an orthogonal cut

In recent years, the finite element method (FEM) has become the main tool for simulating the metal cutting process because research based on trial and error is time consuming and requires high investment. Early studies were done by different investigators. In this research AISI 52100, hardened steel (62 HRC) was selected for an orthogonal machining process as well as metal cutting simulation using the software DEFORM-2D. This software is based on a forging process and has been adapted to an orthogonal machining process. The results of simulated cutting forces were compared with experimental cutting force data to validate the orthogonal cut simulation. Also, the surface roughness was measured, and the influence of the stress, strain, and temperature on the surface roughness was studied.     

冲压模具激光表面强化的搭接工艺研究

针对激光相变强化搭接带存在的回火软化等问题,对激光强化的球墨铸铁材料QT700-2搭接区的显微硬度、表面粗糙度、物相变化等进行了测试,并分析了强化机理。结果表明:选用合理的搭接率等工艺参数,球墨铸铁激光搭接强化后的硬度可达到50HRC以上,调节搭接宽度可以避免搭接区的回火软化问题。多道搭接强化后表层的马氏体组织呈区域性交错分布,材料表面形成非均匀、多尺度强化结构,强化后的表面具有良好的耐磨性和耐疲劳性。通过上述结果,对材料激光搭接强化的工艺参数进行了合理的优化。     

运用复合剂制备WC颗粒增强钢基表面复合材料

以ZG310-570为基体、WC颗粒为增强相,在普通水玻璃石英砂干型、无负压条件下,运用自制的复合剂,制备出WC颗粒增强钢基表面复合材料.抗磨料磨损性能是含20%Cr高铬铸铁的3.30倍.硬度可达60HRC以上.铸件表面平整光洁,尺寸精度大为提高.合金层厚度均匀,可达8mm,且与基体之间结合良好.     

压印模具表面织构电火花成形工艺参数的分析

在石墨电极表面制备了直径分别为ø100、ø200和ø300 μm且具有规则形貌的圆形微凹坑阵列,并使用该电极在45钢表面利用电火花成形工艺(Electrical discharge machining,EDM)制备出微凸起阵列压印模具,研究了加工电流对其表面性能的影响。采用超景深显微镜和扫描电镜对经电火花加工处理后的石墨电极和45钢试样的表面形貌进行了分析,同时采用洛氏硬度计、粗糙度测试仪和精度为0.01 mg的电子天平秤等设备对45钢表面微凸起阵列进行了检测,并讨论了加工电流对45钢的材料去除率(Material removal rate,MRR)和石墨电极的电极耗损率(Electrode wear rate,EWR)之间的影响规律。结果表明,电火花反刻原理可以在45钢表面形成尺寸相对应的微凸起阵列形貌,并得到较高的表面显微硬度和表面粗糙度值,随着电火花加工电流的增大而增大,其中,ø200 μm微凸起试样得到了最大显微硬度,为34 HRC,同时,ø300 μm微凸起试样得到了最大表面粗糙度值12.56 μm。此外,当试样微凹坑或微凸起直径一定时,随着加工电流的增大,MRR和EWR值也会随之增大。     

Effects of deformation behavior on fatigue fracture surface morphology in a nickel-base superalloy

Fatigue crack propagation fracture surface morphologies in nickel-base superalloys vary substantially with changes in loading parameters such as temperature, ΔK, load ratio, frequency, and additionally microstructure. Quantitative fracture surface roughness can vary from sub-micron levels to a maximum value of approximately half the grain size. Atomic Force Microscope studies of surface slip traces in compression specimens revealed a clear relationship between slip homogeneity in compression testing and fracture surface roughness under similar fatigue loading conditions. It has been shown in this study that changes in ΔK, strain level, temperature, grain size, and load ratio can all affect slip heterogeneity, which in turn controls the fracture surface roughness. Finally, a model is developed that quantitatively predicts fracture surface roughness and roughness-induced crack closure stress intensity values from measurements of slip line spacing in a compression specimen.     

Theoretical analysis of silicon surface roughness induced by plasma etching

A theoretical study of single-crystal silicon surface roughness induced by SF₆ plasma has been carried out by means of atomic force microscopy. Plasma which contains the velocity shear instability has been used to study the relation between the plasma parameters and subsequent surface roughness. The surface roughness has been examined in the dependence on experimental parameters. The results obtained by theoretical calculations are identical to the experimental ones. The present paper has quantified the influence of a DC electric field values on plasma parameters such as the ratio of ion flux to the neutral reactant flux (J ⁺/J _F), exposure time, DC electric field, magnetic field and inhomogeneity. Theoretical investigation shows that the roughness of silicon surface increases with the increase of the values of J ⁺/J _F, exposure time, of magnetic field, of inhomogeneity in a DC electric field and decreases through increasing the value of a DC electric field.     

Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool

The present work concerns an experimental study of hard turning with CBN tool of AISI 52100 bearing steel, hardened at 64 HRC. The main objectives are firstly focused on delimiting the hard turning domain and investigating tool wear and forces behaviour evolution versus variations of workpiece hardness and cutting speed. Secondly, the relationship between cutting parameters (cutting speed, feed rate and depth of cut) and machining output variables (surface roughness, cutting forces) through the response surface methodology (RSM) are analysed and modeled. The combined effects of the cutting parameters on machining output variables are investigated while employing the analysis of variance (ANOVA). The quadratic model of RSM associated with response optimization technique and composite desirability was used to find optimum values of machining parameters with respect to objectives (surface roughness and cutting force values). Results show how much surface roughness is mainly influenced by feed rate and cutting speed. Also, it is underlined that the thrust force is the highest of cutting force components, and it is highly sensitive to workpiece hardness, negative rake angle and tool wear evolution. Finally, the depth of cut exhibits maximum influence on cutting forces as compared to the feed rate and cutting speed.     

基于RP/RT技术的不锈钢快速模具制造工艺

用基于RP/RT技术的等离子喷涂制模技术制造不锈钢快速模具 ,与传统钢制模具相比 ,该工艺可以缩短模具开发周期60% ,成本也只有传统钢模的15%～20% ,非常适合新产品的开发和单件小批量产品的生产。介绍了该工艺的原理 ,讨论了成形的技术关键,运用该工艺进行不锈钢快速模具试制 ,不锈钢喷涂层厚度达到5mm ,表面硬度达到34.4HRC ,抛光后表面粗糙度达到Ra=0.2μm。     

PCBN微型铣刀的制备及应用

聚晶立方氮化硼(PCBN)刀具具有高硬度、高耐磨性、较好的导热性、较低的摩擦系数,同时又具有优良的化学稳定性、热稳定性及加工红硬性,可以以铣磨方式高效加工高硬度、高强度、耐腐蚀性钢材并获得高表面加工质量。在分析PCBN微型铣刀的设计特点与加工难点基础上,成功制备了颈部缩颈3 mm,直径0.2 、0.4 、0.6 以及1.0 mm的PCBN微型球头双螺旋刃铣刀,并使用直径0.4 mm的微型铣刀进行铣削实验。结果表明:制备的PCBN微型铣刀可以高质量、高效率地加工硬度50 HRC的模具钢模具,模具的表面粗糙度R_a值可达0.101 μm,且无阴阳面,满足其表面最终加工要求。