半固着磨具特性对其磨耗和工件材料去除的影响

为获得先进陶瓷材料的高效、高精度加工,通过采用新研制的半固着磨具来实现一种半固着磨粒加工技术．制作了以SiC为磨料的不同粒度和磨料浓度的半固着磨具（SFAT）,讨论分析了磨料粒度和磨料浓度对半固着磨具特性（剪切强度和表面硬度等）的影响．采用所制作的半固着磨具加工单晶硅片,研究半固着磨具的磨耗率和工件材料去除率．初步实验结果表明,磨料粒度#1000和磨料质量分数为65％的半固着磨具的磨具磨耗率最小且工件材料去除率最大．实验结果有助于指导半固着磨具制作．     

Optimization of Electrical Discharge Machining Characteristics of SiCp/LM25 Al Composites Using Goal Programming

In the present study an effort has been made to optimize the machining conditions for electric discharge machining of LM25 Al (7 Si, 0.33 Mg, 0.3 Mn, 0.5 Fe, 0.1 Cu, 0.1 Ni,.2 Ti) reinforced with green bonded SiC particles with approximate size of 25 mum. Polynomial models were developed for the various EDM characteristics such as metal removal rate, tool wear rate and surface roughness in terms of the process parameters such as volume fraction of SK, current and pulse time. The models were used to optimize the EDM characteristics using nonlinear goal programming.     

Effect of abrasive jet process parameters on machining glass fibre reinforced polymer composite

An experimental and theoretical research work on abrasive jet machining of glass fiber reinforced polymer composite materials was conducted using abrasive jet machining setup fabricated in our workshop. The objective of this research work is to machine holes on the glass fiber reinforced polymer composite using an abrasive jet machine under various levels of process parameter. The material removal rate and hole geometry (kerf analysis) were observed as a part of the investigation. Four factors five levels central composite rotatable design matrix was used for optimizing the required number of experiments. The objective of the present investigation is to develop mathematical models using the response surface methodology. The adequacy of the models has been checked using the ANOVA technique. Use of the developed mathematical models, material removal rate and hole geometry of the machined glass fibre reinforced polymer composite helps prediction at 95% confidence level.     

Enhanced wear resistance of hybrid PTFE/Kevlar fabric/phenolic composite by cryogenic treatment

Hybrid PTFE/Kevlar fabric was treated by cryogenic approach. The untreated or cryo-treated fabric was incorporated into fabric/phenolic composite for friction and wear tests. It was found that the wear resistance of the fabric/phenolic composite was improved after cryo-treatment, although the friction coefficient increased to a certain extent. SEM observations showed that the roughness of hybrid fabric increased by cryo-treatment, which may enhance the mechanical interlocking of the phenolic resin on the fiber surface. Enhanced fiber/resin adhesion was considered to contribute to the improved wear resistance of cryo-treated fabric/phenolic composite.     

Electrical Discharge Machining of Functionally Graded 15-35 Vol% SiCp/Al Composites

A functionally Graded 15-35 volume% silicon carbide particulate (SiC_p) reinforced Al359 metal matrix composite (SiC_p/Al MMC) was drilled by electrical discharge machining (EDM) to assess the machinability and workpiece quality. The machining conditions were identified for both the machining performance and workpiece quality of the EDM process, including some aspects of material removal mechanisms, material removal rate (MRR), electrode tool wear, and subsequent drilled hole quality including surface texture and roundness by using surface profilometry, coordinate measuring machine (CMM), and scanning electron microscopy (SEM). It was observed that the material removal rate increases with increasing peak current and pulse-on-time up to the optimal points and drops drastically thereafter. Higher peak current and/or pulse-on-time result in both the greater tool wear and the larger average diameter error. As the percentage of the SiC particles increases, MRR was increased and electrode wear was found to be decreased. At the EDM machined subsurface layer, the fragmented and melted SiC particles were observed under the SEM and EDX-ray examination.     

Influence of cryogenic coolant on turning performance characteristics: A comparison with wet machining

Machining of 17-4 Precipitation Hardenable Stainless Steel (PH SS) is one of the difficult tasks because of its high cutting temperatures. Conventional cutting fluids are used to overcome the high cutting temperatures, but these are not acceptable from the health and environmental sustainable points of view. Cryogenic cooling is one of the potential techniques to overcome such problems. In the current work, comparison is made of cryogenic turning results, such as tool flank wear, cutting forces (feed force, main cutting force), cutting temperature, chip morphology and surface integrity characteristics with wet machining during machining of heat-treated 17-4 PH SS. The result showed that in cryogenic machining, a maximum of 53%, 78%, 35% and 16% reductions was observed in tool flank wear, cutting temperature, surface roughness and cutting force, respectively, when compared with wet machining. It was also evident from the experimental results that cryogenic machining significantly improved the machining performance and product quality even at high feed rates.     

Development of ANFIS model and machinability study on dry turning of cryo-treated PH stainless steel with various inserts

This present investigation deals about the machinability comparison of cryogenically treated 15-5 PH stainless steel with various cutting tools such as uncoated tungsten carbide, cryogenic-treated tungsten carbide and wiper geometry inserts. Cryo-treated PH stainless steel is considered as the work material in this investigation and experimental trials were performed under dry turning condition. The machinability aspects considered for evaluation are cutting force (F_z), surface roughness (R_a) and tool wear. The outcomes of experimentation reveal that the tungsten carbide inserts which are cryogenically treated provide improved performance in machining while comparing with conventional and wiper geometry inserts at all machining conditions. The measured cutting force and the observed flank wear were less for the cryo-treated inserts. However, wiper tool produces a better surface finish during machining. An artificial intelligence decision-making tool named Adaptive Neuro Fuzzy Inference System has been evolved to determine the relation among the considered input machining variables and output measures, namely cutting force and surface roughness of the machined surface. An analysis has been performed to compare the results obtained from developed models and experimental results.     

Taguchi optimization of machining parameters in drilling of AISI D2 steel using cryo-treated carbide drills

This study focused on using the Taguchi technique to optimize the process parameters in drilling of AISI D2 steel with carbide drills to minimize the surface roughness (Ra) and thrust forces (Ff). The drilling experiments were conducted on a CNC vertical machining centre according to the L18 experimental design. Uncoated drills were classified into three groups: untreated (U), cryo-treated (CT) and cryo-treated and tempered (CTT). The experimental results showed that the CTT drills exhibited the best performance in terms of Ra and Ff due to the improved wear resistance of carbide drills after the cryogenic treatment and tempering. As a result of analysis of variance (ANOVA), it was found that the most influential parameter on both Ra and Ff was the feed rate, with percentage contributions of 66.97% and 80.07%, respectively. The results showed that the Taguchi technique is a powerful method to optimize the process parameters in drilling of tool steel.     

Machining Characteristics of Inconel 718 by Sinking-EDM and Wire-EDM

Inconel 718 superalloy has wide applications in several industries due to its excellent mechanical properties. However, it is very difficult to machine using conventional cutting and grinding because of its high strength at elevated temperatures. Electrical discharge machining (EDM) is an alternative competitive process to machine Inconel alloys by electrical erosion. However, machinability and surface characteristics of EDMed Inconel surfaces are poorly understood. This study focuses on the machining characteristics of Inconel 718 by Wire-EDM and Sinking-EDM with a new Cu-SiC electrode, respectively. Material removal efficiency, surface roughness, surface topography, surface alloying, and electrode wear have been characterized. It is found that the high toughness of Inconel 718 would be the major contributing factor to the absence of microcracks on the EDMed surface. The new fabricated Cu-SiC electrode for Sinking-EDM has better performance in terms of material removal rate (MRR), surface roughness, and electrode wear. The higher melting temperature and fine microstructure of SiC contribute to the lower electrode wear of the new Cu-SiC electrode than the traditional Cu electrode.     

Multiple Performance Optimization of Machining Parameters on the Machining of GFRP Composites Using Carbide (K10) Tool

The present investigation focuses on the multiple performance machining characteristics of GFRP composites produced through filament winding. Grey relational analysis was used for the optimization of the machining parameters on machining GFRP composites using carbide (K10) tool. According to the Taguchi quality concept, a L27, 3-level orthogonal array was chosen for the experiments. The machining parameters namely work piece fiber orientation, cutting speed, feed rate, depth of cut and machining time have been optimized based on the multiple performance characteristics including material removal rate, tool wear, surface roughness and specific cutting pressure. Experimental results have shown that machining performance in the composite machining process can be improved effectively by using this approach.     

Effect of deep cryotreated tungsten carbide electrode and SiC powder on EDM performance of AISI 304

Abstract

Powder mixed electric discharge machining (PMEDM) is a further advancement of conventional EDM process in which electrically conductive powder is suspended in the dielectric fluid to enhance the material removal rate (MRR) along with the surface quality. Cryotreatment is introduced in this process for improving the cutting tool properties as well as tool life. In this investigation, EDM is performed for the machining of AISI 304 stainless steel using cryotreated double tempered tungsten carbide electrode when SiC powder is suspended in the kerosene dielectric. The influence of process parameters viz. pulse on time, peak current, duty cycle, gap voltage and powder concentration on tool wear rate (TWR), surface roughness (R_a), and MRR has been studied. Metallographic analysis was carried out for the machined surfaces. By the addition of powder concentration and cryotreated double tempered electrode, significant improvement in the machining efficiency has been found out. When cryotreated electrode used MRR, TWR and R_a decreased by 12%, 24% and 13.3%, respectively and when SiC powder used MRR increased by 23.2%, TWR and R_a decreased by about 25% and 14.2%, respectively.     

液体磁性磨具小孔光整加工材料去除机理及实验

针对小孔内壁光整加工技术的难题,本文提出一种新型精密研磨孔光整加工技术,以磁致相变理论为指导,从微观角度阐述了液体磁性磨具研磨孔光整加工的材料去除机理.采用"双刃圆半径"模型进行单个磨料颗粒切削模型研究,得出小孔光整加工的材料去除率数学表达式.通过实验验证了磨料粒度、入口压力、电流强度等因素对材料去除率以及表面粗糙度的影响,实验结果表明:在合适的范围内,增大磨料颗粒直径、入口压力以及电流强度有利于提高材料的去除率和表面质量.而当磨粒直径、入口压力以及电流强度选取过大时,虽然能获得较高的材料去除率,但是最终获得的表面粗糙度值并不理想.该研究为通孔零件内壁表面精密光整加工提供了有益参考.     

Cryogenic turning of the Ti–6Al–4V alloy with modified cutting tool inserts

Productivity in the machining of titanium alloys is adversely affected by rapid tool wear as a consequence of high cutting zone temperature. Conventional cutting fluids are ineffective in controlling the cutting temperature in the cutting zone. In this research work, an attempt has been made to investigate the effect of liquid nitrogen when it is applied to the rake surface, and the main and auxiliary flank surfaces through holes made in the cutting tool insert during the turning of the Ti–6Al–4V alloy. The cryogenic results of the cutting temperature, cutting forces, surface roughness and tool wear of the modified cutting tool insert have been compared with those of wet machining. It has been observed that in the cryogenic cooling method, the cutting temperature was reduced by 61–66% and the surface roughness was reduced to a maximum of 36% over wet machining. The cutting force was decreased by 35–42% and the flank wear was reduced by 27–39% in cryogenic cooling over that of wet machining. Cryogenic cooling enabled a substantial reduction in the geometry of tool wear through the control of the tool wear mechanisms. The application of liquid nitrogen to the heat generation zones through holes made in the cutting tool insert was considered to be more effective over conventional machining.     

Simplified MQL system for drilling AISI 304 SS using cryogenically treated drills

In machining operations, cutting fluids have been comprehensively used to improve the cutting tool life, but the issues related to manufacturing cost, environment and health call for reducing their use by possible methods. Minimum quantity lubrication (MQL) is a technique that overcomes these problems by spraying a small amount of cutting fluid (<100?ml/hr) as mist using compressed air. In this work, the basic MQL technique is used to achieve flow rates slightly higher (～880?ml/hr) than MQL using simple techniques like paint sprayer and compressor, which is more generally called reduced quantity lubrication (RQL). Another method to increase the tool life is by cryogenic treatment, which increases the hardness of the tool. Tungsten carbide drill bits were subjected to cryogenic treatment (?185 °C). Drilling studies were carried out on AISI 304 stainless steel (SS) using untreated and cryo-treated WC drill bits under RQL and conventional wet lubrication conditions. The tool wear on the treated WC drill bits with RQL was comparatively less than on the untreated ones with RQL and wet lubrication. These improvements were established through microhardness, SEM images, XRD, wear studies and surface roughness measurements comparisons.     

Effects of Filler Concentration and Cutting Parameters on Material Properties and Machinability of SiC-Filled Epoxy Tooling Board

An experimental study was conducted to examine the material properties and machinability of a silicon carbide (SiC)-filled epoxy conductive tooling system (RP4037 CAST-IT^TM). Specifically, the effects of SiC filler concentration and machining process parameters (cutting speed and feed) on the physical and material properties, resultant cutting force, surface integrity, and tool wear were studied. Machinability evaluation was carried out using the end milling process. The study showed that an increase in filler concentration significantly increased the density, thermal conductivity, resultant machining forces, surface roughness of the machined surface, and tool wear. However, it had insignificant impact on the glass transition temperature, strength, or hardness. A decrease in material strength was observed with increasing cutting speed and feed. Increasing filler concentration was also found to degrade the machined surface morphology. Possible explanations for the observed effects are discussed.     

Application of new tool material for electrical discharge machining (EDM)

In EDM, Cu and graphite are commonly used as tool materials. The poor wear resistance is the drawback of these tools. In the current study, an attempt has been made to develop a ZrB₂-Cu composite as an EDM tool material to overcome this problem. Initially, the ZrB₂ powder is prepared by self-propagating high-temperature synthesis (SHS) technique and synthesized powder is mixed with different amounts of Cu powder. Dense composite is developed by a pressureless sintering at 1250°C. The composites are tested as tool material at different EDM process parameters during machining of mild steel. The ZrB₂-40 wt% Cu composite shows highest metal removal rate (MRR) with significant tool removal rate (TRR) than other composites. The performance of ZrB₂-40 wt% Cu composite is compared to conventional Cu tool. The composite shows higher MRR with less TRR than Cu tool but it shows more average surface roughness and diameteral overcut than Cu tool.     

Machinability and surface morphology investigations of multiwall carbon nanotube reinforced aluminium 7075 metal matrix composite during electrical discharge machining: A grey relational approach

Multiwall carbon nanotube buttressed aluminium 7075 metal matrix composite was synthesized through an amended liquid metallurgy method, which consisted semisolid stirring, ultrasonic treatment and squeeze casting. Aim was to investigate its machinability and surface morphology during electrical discharge machining. Variable machining factors were peak current, pulse-on time and gap voltage, whereas the responses under investigation were electrode wear rate, material removal rate and average surface roughness. Results revealed electrode wear rate, material wear rate and average surface roughness increased on increasing peak current and pulse-on time, but all these responses behaved inversely with the increase of gap voltage. Average surface roughness reduced by around 44 % on reducing the peak current from 10 A to 4 A and increasing gap voltage from 55 V to 80 V at constant pulse-on time of 300 μs; however, it increased by around 25 % on reducing the gap voltage from 80 V to 55 V and increasing the pulse-on time from 100 μs to 300 μs at constant peak current of 10 A. Significance of the process parameters were verified, regression models were developed and morphology of the machined surfaces was studied. Finally, multiple response optimization was conducted following grey relational approach.     

Studies on Machining Parameters While Milling Particle Reinforced Hybrid (Al6061/Al2O3/Gr) MMC

In this article, response surface methodology has been used for finding the optimal machining parameters values for cutting force, surface roughness, and tool wear while milling aluminum hybrid composites. In order to perform the experiment, various machining parameters such as feed, cutting speed, depth of cut, and weight (wt) fraction of alumina (Al₂O₃) were planned based on face-centered, central composite design. Stir casting method is used to fabricate the composites with various wt fractions (5%, 10%, and 15%) of Al₂O₃. The multiple regression analysis is used to develop mathematical models, and the models are tested using analysis of variance (ANOVA). Evaluation on the effects and interactions of the machining parameters on the cutting force, surface roughness, and tool wear was carried out using ANOVA. The developed models were used for multiple-response optimization by desirability function approach to determine the optimum machining parameters. The optimum machining parameters obtained from the experimental results showed that lower cutting force, surface roughness, and tool wear can be obtained by employing the combination of higher cutting speed, low feed, lower depth of cut, and higher wt fraction of alumina when face milling hybrid composites using polycrystalline diamond insert.     

Experimental Investigation on Rotary Ultrasonic Face Grinding of SiCp/Al Composites

SiCp/Al composites have been widely used in many fields such as aerospace, automobile, advanced weapon system, etc. But this kind of material, especially with high volume fraction, is difficult to machine due to the reinforced particles existing in matrix, which has limited its further application. Rotary ultrasonic machining (RUM) has many excellent features and it has never been used to machine SiCp/Al composites. In order to improve the machinability and application of SiCp/Al composites, the rotary ultrasonic face grinding experiments of SiCp/Al composites reinforced with 45% volume SiC particles were carried out to investigate cutting force, surface quality, tool wear, and abrasive chip shapes. The experimental results indicate that ultrasonic vibration could reduce cutting force, surface roughness, surface defects, and increase plastic removal ratio. The cutting force could be lowered by an average of 13.86% and the surface roughness could be lowered by an average of 11.53%. The examined results of tool wear patterns suggest that tool wear is mainly caused by grain breakage and grain fall-off. Grinding wheel blockage and grinding burn were not observed in machining process.     

Modeling and Analysis of Machinability Evaluation in the Wire Electrical Discharge Machining (WEDM) Process of Aluminum Oxide-Based Ceramic

The wire electrical discharge machining (WEDM) allowed success in the manufacture of the hard, fragile, and materials difficult to cut, especially for electroconductive ceramic materials. In this study, the mathematical models of material removal rate (MRR) and surface roughness (SR) used for the machinability evaluation in the WEDM process of aluminum oxide-based ceramic material (Al₂O₃ + TiC) have been carried out. The experimental plan adopts the face centered central composite design (CCD). The mathematical models using the response surface methodology (RSM) are developed so as to investigate the influences of four machining parameters, including the peak current, pulse on time, duty factor, and wire speed, on the performance characteristics of MRR and SR. It has been proved that the proposed mathematical models in this study would fit and predict values of the performance characteristics, which would be close to the readings recorded in experiment with a 95% confidence level. The significant parameters that critically affect the performance characteristics are examined.