CRITERIA FOR THE QUALITY ASSESSMENT OF CONSTITUTIVE EQUATIONS DEDICATED TO CUTTING MODELS

Determination of the flow stress under metal cutting conditions is difficult because high values of strains, strain rates and temperature exist in practical machining operations. Conventional tests for determining flow stress data cannot duplicate these deformation conditions and therefore, extrapolation will be required. In this study we have investigated critical issues regarding the constitutive equation determination by direct methods such as split Hopkinson's pressure bar bench (SHPB) tests. Quantitative analysis about the suitability of an experimentally determined constitutive equation for different purpose modeling is provided, leading to guidelines for the quality improvement of constitutive law dedicated to cutting, from the points of view of formulation and identification sequence.     

数控加工的基本坐标系和对刀问题

数控加工中的对刀问题影响机械加工的各个方面。这里从介绍数控机床的基本坐标系出发，重点阐述了对刀的基本原理和方法以及常见数控机床对刀问题的处理。     

升深2-17井络合铝聚合物充气钻井液现场试验

为加快徐加固子深层天然气的勘探开发步伐，缩短深层气井的建井周期，在升深2-17井进行了充气钻井试验。介绍了络合铝聚合物充气钻井液技术的现场应用概况及效果以及井漏的发生与处理过程、钻井液起泡的解决措施。在现场试验过程中，络合铝聚合物钻井液性能稳定，具有较强的抑制性和较好的流变性能，流性指数控制在0．7左右，具有良好的携屑和稳定井壁能力，而且粘度较低，基本上控制在33～52s之间，满足了现场充气和脱气的需要；该钻井液抗温可达180℃，润滑性能较好，在钻井过程中无粘卡显示，在深井欠平衡井眼稳定方面取得了较好的效果；在不同的气液比条件下，可以在0．83～1．08g／cm。之间实现对当量密度的调节;与常规钻井工艺相比，充气钻井可以使机械钻速提高30％～50％；在钻进过程中实现了充气和点火同时进行，达到了欠平衡钻井工艺技术的要求，为进一步开展气体钻井打下了良好的基础。     

Experimental results of a low-power roadheader driving a gallery with different types of rock at the face

In this paper, the experimental results of a 45-kW and 15-t roadheader excavating a gallery with two different types of rock at the face using two different cutting heads are shown. It is proved that the roadheader works properly with both cutting heads. In comparison with other results in the literature, the principal parameters, i.e. specific energy, cutting rate and tool wear, are at a level that can be considered satisfactory taking into account the low power of the roadheader. On the other hand, the influence of the number of picks, which is the main difference between the two cutting heads, on the operational parameters is shown.     

发动机连杆螺纹孔加工质量的改进

对发动机连杆螺纹孔在攻丝过程中出现烂牙、粗糙度差等加工质量问题进行了分析，提出了解决问题的方法，使连杆的合格率行到显著的提高。     

A computational study of LP-based heuristic algorithms for two-dimensional guillotine cutting stock problems

In this paper we develop and compare several heuristic methods for solving the general two-dimensional cutting stock problem. We follow the Gilmore-Gomory column generation scheme in which at each iteration a new cutting pattern is obtained as the solution of a subproblem on one stock sheet. For solving this subproblem, in addition to classical dynamic programming, we have developed three heuristic procedures of increasing complexity, based on GRASP and Tabu Search techniques, producing solutions differing in quality and in time requirements. In order to obtain integer solutions from the fractional solutions of the Gilmore-Gomory process, we compare three rounding procedures, rounding up, truncated branch and bound and the solution of a residual problem. We have coded and tested all the combinations of algorithms and rounding procedures. The computational results obtained on a set of randomly generated test problems show their relative efficiency and allow the potential user to choose from among them, according to the available computing time. Rceived: January 9, 2001 / Accepted: December 10, 2001     

Effects of circumferential pick spacing on boom type roadheader cutting head performance

Effects of equal and unequal circumferential pick spacing on the performance of boom type roadheaders having cylindrical cutting heads are investigated. For this purpose, two experimental cutting heads with equal and unequal circumferential spacing are designed and manufactured. The cutting head with unequal circumferential spacing is specifically designed to prevent tool-holder overlap at the nose section. Manufacturing difficulties associated with equal circumferential pick spacing due to tool-holder overlap are discussed with solid modeling and practical applications. The heads are tested at Park Cayirhan Coal Mine in Turkey and their cutting performances are analysed. Although better cutting performance for equal circumferential spacing are predicted by force–balance analysis, in situ measurements of instantaneous (net) traversing speed and cutting rate, pick consumption rate and machine vibration show that no significant difference exists between the performances of the two cutting heads.     

The statistical modeling of surface roughness in high-speed flat end milling

Surface roughness is one of the most important requirements in machining process. The surface roughness value is a result of the tool wear. When tool wear increase, the surface roughness also increases. The determination of the sufficient cutting parameters is a very important process obtained by means of both minimum surface roughness values and long tool life. The statistical models were developed to predict the surface roughness.This paper presents the development of a statistical model for surface roughness estimation in a high-speed flat end milling process under wet cutting conditions, using machining variables such as spindle speed, feed rate, depth of cut, and step over. First- and second-order models were developed using experimental results of a rotatable central composite design, and assessed by means of various statistical tests. The highest coefficient of correlation (R_adj²) (88%) was obtained with a 10-parameter second-order model. Meanwhile, a time trend was observed in residual values between model predictions and experimental data, reflecting the probable effect of the tool wear on surface roughness. Thus, in order to enhance the estimation capability of the model, another independent variable was included into the model to account for the effect of the tool wear, and the total operating time of the tool was selected as the most suitable variable for this purpose. By inserting this new variable as a linear term into the model, R_adj² was increased to 94% and a good fit was observed between the model predictions and supplementary experimental data.In this study, it was observed that, the order of significance of the main variables is as X₅>X₃>X₄>X₁>X₂ (total machining time, depth of cut, step over, spindle speed and feed rate, respectively).     

三维CAD在成形车刀截形设计中的应用

介绍了运用投影原理，在三维CAD中作出零件的三维造型，并依此生成二维工程图，在二维工程图中进行标注，从而得到准确的成形车刀截形尺寸数据的方法。该方法兼具作图法直观与计算法准确的优点，为工程设计与计算提供了一种新的思路。     

Novel methods for rapid assessment of tool performance in milling

The paper examines the effectiveness of two innovative techniques designed to rapidly optimize a milling application. One of them relates to quantifying the relative wear of different insert grades concurrently in a single cutting test, by mounting the inserts in the same cutter, for a quick comparative performance evaluation. Experimental results that illustrate the validity and limitation of this concept, and a scheme for enhancing the reliability of the test method are presented. The other technique refers to rapid identification of the optimum feed/tooth that corresponds to maximum tool life. This entails a test wherein individual inserts in the cutter are subject to feed/tooth that are multiples of a base value, by selectively leaving appropriate number of consecutive insert pockets unoccupied. These novel techniques complement known accelerated tool life tests, and are expedient for industries that engage short production runs, in terms of selecting a suitable insert grade for an application, and determining optimal cutting conditions for the selected grade.