STUDY ON NEAR DRY CUTTING OF ALUMINUM ALLOYS

Series of orthogonal cutting tests of aluminum alloys with different amount of silicon content have been carried out to investigate the chip formation process and adhesion of the work material to the rake face of the cutting tool under near dry cutting conditions. No adhesion is observed when cut with the sintered diamond tool regardless of the amount of the silicon content. On the other hand, the amount of adhesion increases with an increase in the silicon content in the aluminum alloys when cut with the cemented carbide and DLC-coated tools. No adhesion is formed when the nominal coefficient of friction on the rake face is 0.3 or less, and adhesion is formed when the nominal coefficient of friction is 0.4 or more. The amount of adhesion decreases with an increase in the rake angle when cut with the cemented carbide tools and the DLC-coated tool.     

铝合金超声疲劳行为研究

研究LY10、LY12、2219、6061和AS5U3G—Y35五种铝合金的超声疲劳行为。获得的6条S-N曲线显示，铝合金在10^7～10^10疲劳周次区间仍然发生疲劳断裂，N=10^10时的疲劳强度显著低于N=10^7时的疲劳强度。断口分析表明，铝合金对表面完整性极其敏感。与黑色金属和钛合金不同，铝合金试件在极高周次疲劳中，裂纹仍然主要由表面或次表面起裂。铝合金试件的疲劳断口没有发现明显的“鱼眼”现象和黑影区。超声频率下极高的应变速率和位错移动速率增加了脆性质点开裂和沉淀相的溶解现象，引起微观组织局部失效，从而形成疲劳裂纹的萌生和扩展。     

nm硬质合金刀具切削性能的研究

在切削试验研究的基础上,对比了ｎｍ硬质合金刀具与普通硬质合金刀具的切削性能。试验结果表明,ｎｍ硬质合金刀具由于晶粒细化可以改善刀具的切削性能,提高抗破损性和刀具寿命。ｎｍ硬质合金可为自动化生产提供一种性能优良的刀具材料,有广泛的推广前景。     

切削过程的分叉与突变

根据非自由切削模型和切削试验研究了切屑流动的分叉突变原理,结果表明：在切削层图形系数gs＝1的两侧有两个分叉点gs1和gs2,形成一个分叉区间（gs1,gs2）;单位切削功率的连续多极值取向是切屑流动分叉的原因;在分叉区间切屑流动状态的改变呈现出典型的尖点突变特征;突变的滞后性对切削力及切屑旋向有明显的影响。     

INFLUENCE OF FRICTION AND PROCESS PARAMETERS ON THE SPECIFIC CUTTING FORCE AND SURFACE CHARACTERISTICS IN MICRO CUTTING

For the production of small quantities of micro devices, machining is a low cost alternative to lithographic processing techniques. However, machining shows process specific size-effects upon miniaturization to the micrometer regime. Hence, the orthogonal turning process is chosen to study the influence of process parameters like uncut chip thickness h, cutting velocity v_c and cutting edge radius r_β on the cutting force and the surface plastification by two-dimensional, thermo-mechanically coupled finite element simulations. A rate-dependent plasticity law is used for investigation of a normalized medium carbon steel (AISI 1045). Furthermore, the characteristics of the influences of the different parameters are analyzed mathematically by similarity mechanics. In particular, the frictional effects on the cutting process are studied in detail using a friction coefficient μ based on experimental results, and the influences of the process parameters on the cutting force and the plastic deformation of the surface layer are determined numerically. These results are compared with experimental measurements. The specific cutting forces are analyzed and discussed in detail. Size-effects observed experimentally are also found by numerical simulations.     

数控加工三维实时仿真系统的研究

针对数控加工三维实时仿真系统的开发,研究了加工过程三维几何模型构建、仿真过程的实时动态显示以及基于全局光照明的加工环境光照计算的具体方法。根据数控车削加工的特点,提出了一个基于构造单元的工件分解表达模型,利用此模型与刀具实体模型做布尔减运算,来实时模拟工件材料的去除过程及验证加工结果;同时,采用全局光照明模型建立了数控加工的三维仿真环境。实际应用表明,上述模型可以获得理想的真实感效果和仿真速度。     

基于正交切削模拟的零件铣削加工变形预测研究

提出了基于正交切削模拟的零件铣削加工变形的预测方法,建立了三维铣削加工的有限元模型。基于正交切削加工模拟结果,利用铣削温度、铣削力的分析模型求解了三维铣削加工的瞬态温度和瞬态切削力,并将其作为动态载荷应用于三维切削加工的有限元模型,模拟了零件的三维铣削加工过程,预测了零件的变形。通过模拟结果与现场加工情况对比,证明该预测方法是行之有效的。     

A MACHINING PERFORMANCE STUDY IN DRY CONTOUR TURNING OF ALUMINUM ALLOYS WITH FLAT-FACED AND GROOVED DIAMOND TOOLS

This paper presents the results from an experimental study of dry contour turning operations on aluminum alloys (6061B and 2011-T3) using PCD flat-faced and diamond coated grooved tools. The machining performance is assessed on the basis of cutting forces, chip flow, chip-form and surface roughness observed during contour turning operations. The constantly varying cutting conditions (especially effective depth of cut due to varying geometry of the contour surface) and effective tool geometry cause a wide fluctuation in cutting forces and the ensuing chip flow. The chip flow angle is measured along the contour geometry using high-speed filming techniques and these results are compared with predicted chip flow values from the measured experimental cutting forces (which are measured along the entire contour geometry). The resultant surface roughness at different locations along the contour profile is measured and correlated with the chip flow and chip-form variations. Machining performance issues specifically relevant to dry contour turning of aluminum (such as problems due to poor chip flow and the resultant poor surface roughness) are studied and the effectiveness of selective work-tool (both tool material and tool geometry) pairs is illustrated.     

铝合金电阻点焊中电极点蚀对焊接质量的影响

采用有限元和物理模拟方法,考察了铝合金AA5182电阻点焊过程中电极点蚀对焊接质量的影响。结果表明:当电极尖端点蚀面积增加时,电极与试件界面上的实际接触面积基本不变,而试件与试件界面上的接触面积显著增加,电流密度大大减小,形成熔核的厚度和直径都减小。物理模拟试验所得熔核的形状和尺寸与有限元法预测结果符合很好。物理模拟和数值模拟都表明,点蚀孔直径为5.0mm时,只能形成厚度十分有限的环状熔核。研究揭示:电极尖端点蚀导致被连接试件之间的接触面积增大是其影响焊接质量的主要原因之一。     

铝合金点焊前期温度场特征的研究

铝合金点焊是一个高度非线性的力、热、电相耦合的复杂过程,其接触电阻同时具有分布上的随机性和变化上的高度非线性双重特征。在深入分析铝合金点焊电接触特点的基础上建立了一种新的接触电阻数学模型,并利用该模型对其点焊加热前期的温度场进行了数值模拟。结果表明,在通电的第一个1/4周波内,温度场分布极不均匀,电极的烧损与飞溅等缺陷主要发生在这一阶段;在第一个半波内,熔核已经基本形成;结果还表明,在铝合金的点焊中,电极的局部烧损与粘连是很难避免的。     

变滑动磨擦系数振动系统最优化计算方法研究

研究了两自由度滑动摩擦系数随相对速度变化的干摩擦振动系统简谐激励响应计算问题,通过将干摩擦力中的理想干摩擦力（Coulomb dry friction)部分进行Fourier级数展开,取级数展开的第一项作为近似,结合一次谐波平衡法,推导出了系统的非线性频响方程组,运用最优化理论中求解非线性方程组的梯度算法,给出非线性频响方程组的数值迭代格式,最后,通过一个数值例分析讨论了干摩擦力对系统响应的重要作用。     

铝锂合金热变形穿晶韧性断裂原因分析

采用Gleeble-1500热／力模拟试验机，对铸态1420铝锂合金在变形温度为350℃-450℃、应变速率为0．01s^-1-10.0s^-1的条件下，进行高温拉伸热模拟实验研究。利用扫描电镜，能谱分析、X射线衍射以及金相实验等手段对该合金的热变形穿晶韧性断裂进行分析。结果表明，Al3Fe相的存在是引起1420铝锂合金热变形穿晶韧性断裂的根本原因。     

油润滑对微动摩擦特性影响的研究

研究了钢摩擦副在油润滑工况下不同位移幅值对微动润滑摩擦特性的影响,分析了表面形貌。研究表明微动过程中表面之间的油介质会被驱除出接触区域,而滑动过程中表面之间的油介质始终保持在接触区域;润滑油的存在对接触区域起到了遮盖的作用,减少了氧化反应;由于油的流动性,在微动过程中容易再次渗透到接触区域,降低了表面摩擦与磨损。     

利用非晶态合金进行平面应力磁测法的研究

基于铁磁材料压磁效应的应力测量是一种新技术。目前对该技术的研究重点是如何提高它的测试准确性和灵敏度。非晶态合金材料具有良好的磁特性,可以用于应力测量。文中对这种应变计的工作原理及其磁输出特性进行理论分析,并利用铁基非晶态合金薄带进行实测试验。试验结果显示,该方法具有测试灵敏度高、测试系统简单等特点,是一种很有发展前景的应力测试方法。     

进给方向毛刺抑制技术的研究

在对金属切削中进给方向毛刺生成机理进行试验研究和理论分析的基础上，给出了表示产生Ⅰ型微小进给方向毛刺的重要物理量──刀具临界主偏角β_（ｒＩ）。讨论了有关主要因素对临界主偏角的影响，进而开发出了几种抑制或减小进给方向毛刺的新工艺和新方法。     

二维切削中切削方向毛刺与亏缺的界限转换条件

建立了二维切削中切削方向毛刺与亏的生成模型,给出了切削方向毛刺与亏缺的判别准则,并对影响切削方向毛刺与亏缺转换的主要因素进行了实验研究和相应的理论分析,提示出切削方向毛刺与亏缺的界限转换条件为：剪切应变ε≤3,为亏缺;3＜ε＜4,为过渡区;ε＞4,为毛刺。并且,切削方向毛刺与亏缺的界限转换条件因切削条件变化而变化。为进一步深入研究切削毛刺的生成与抑制理论提供了科学的基础。     

局部法评定铝合金3A21角接接头疲劳性能

局部法是近年来应用于焊接接头疲劳评定的一种新方法。文中采用铝合金3A21角接焊缝的拉伸疲劳试验结果就Dang Van准测的局部法对铝合金焊接接头疲劳评定的有效性进行研究,用三维有限元方法计算角焊缝的最大主应力和铝合金焊接接头的残余应力,并分析有限元单元尺寸对局部法评定的影响。结果表明,适用于钢接头的局部法不适用于铝合金焊接接头,将材料常数修正为α=0．5、β=50MPa后,评定结果与试验结果相符合。有限元网格尺寸对局部参数βexp评定有一定影响,当最小单元尺寸小于0．65mm,单元尺寸对评定结果的影响较小。     

水下切割环境的实现及射流冲蚀性能试验研究

提出了水下射流切割模拟试验装置模型并对其进行了分析与试验。实现了水下切割环境。试验研究了模拟水深、靶距及冲蚀时间对水下射流性能的影响关系,较全面地揭示了水下射流的特性。     

含有泡沫铝芯的复合板弯曲断裂行为的原位研究

对由泡沫金属铝芯和金属面板组成的三层和多层复合板四点弯曲条件下的变形和断裂行为进行原位观察。研究结果表明：在弯曲条件下,复合板有两种基本的破坏方式,一种是复合板表面凹陷(Indentation, ID),它是表面局部集中塑性变形的结果;另一种是泡沫铝内芯切断 (Core shear, CS),它是内芯在最大切应力作用下的破坏。对一个给定的三层复合板,当凹陷破坏的载荷极限FID大于内芯切断的载荷极限FCS时发生内芯切断式破坏,反之发生表面凹陷式破坏。对于多层复合板,破坏方式受金属面板制约,不能直接应用三层板的破坏判据。若三层板发生凹陷型破坏,具有与三层板相同金属面板厚度的多层复合板发生凹陷加内芯切断的混合型破坏。当三层板只发生内芯切断型破坏时,具有与三层板相同金属面板厚度的多层复合板完全发生内芯切断型破坏。     

EFFECT OF CUTTING SPEED AND SURFACE CHEMISTRY OF CUTTING TOOLS ON THE FORMATION OF BUL OR BUE AND SURFACE QUALITY OF THE GENERATED SURFACE IN DRY TURNING OF AA6005 ALUMINIUM ALLOY

In the present investigation, AA6005 (ISO: AlSiMg) alloy was machined in turning operation with different cutting tools, such as uncoated cemented carbide insert, PVD TiN coated, CVD diamond coated and PCD insert, under dry environment. Effect of cutting speed was studied for each of the cutting tools with regard to the formation of built-up layer (BUL) or built-up edge (BUE). The rake surface of the tools was characterized by optical microscopy, scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) spectroscopic microanalysis. Particular emphasis was given on wear mechanism of PVD TiN coated insert, conventionally used in machining ferrous alloys, during dry turning of AA6005 alloy. It has been observed that increase of cutting speed from 200 m/min to as high as 1000 m/min could not substantially reduce formation of BUL over tool rake surface during dry machining of AA6005 alloy with uncoated or PVD TiN coated cemented carbide inserts. The potential of diamond-based tools in dry machining of aluminium alloy was also studied. Finally, the effect of cutting speed on surface finish of the workpiece machined with different cutting tools was studied during dry turning of AA6005 alloy.