Surface Roughness Analysis in Machining of Titanium Alloy

The use of response surface methodology for minimizing the surface roughness in machining titanium alloy, a topic of current interest, has been discussed in this article. The surface roughness model has been developed in terms of cutting parameters such as cutting speed, feed, and depth of cut. Machining tests have been carried out using CVD (TiN-TiCN-Al₂O₃-TiN) coated carbide insert under different cutting conditions using Taguchi's orthogonal array. The experimental results have been investigated using analysis of variance (ANOVA). The results indicated that the feed rate is the main influencing factor on surface roughness. Surface roughness increased with increasing feed rate, but decreased with increasing cutting speed and depth of cut. The predicted results are fairly close to experimental values and hence, the developed models can be used for prediction satisfactorily.     

高表面粗糙度6061铝合金的两酸抛光工艺研究

目的 为了降低6061铝合金的表面粗糙度,提出了一种环保型的两酸化学抛光工艺,并探究了抛光工艺条件对6061铝合金表面粗糙度和表面形貌的影响。方法 采用正交实验设计,确定6061铝合金两酸抛光添加剂的浓度,在此基础上通过单因素实验进一步对抛光液配方、温度和时间进行参数优化。通过粗糙度仪测量抛光前后的粗糙度和表面轮廓曲线,利用金相显微镜观察抛光前后的微观表面和断面金相,并且计算最佳工艺下的失重率。结果 在温度100 ℃、抛光10 min条件下,当抛光液的成分为H3PO4+H2SO4(质量比为2︰1)、10 g/L硫酸铝、2 g/L硫酸铜、1.6 g/L金属盐A、3 g/L氧化剂B、15 g/L过硫酸铵、1.5 g/L钼酸铵时,抛光效果最好。在最佳工艺下进行抛光,使铝合金表面粗糙度从6~8 µm降低至2 µm左右,粗糙度的标准差从2 µm左右降低至1 µm以下,失重率在0.002~0.004 g/(cm².min)范围内波动,并且得到了光亮的表面。结论 该抛光体系在处理高表面粗糙度的6061铝合金时表现出良好的抛光效果,研究结果对提高3D打印的6061铝合金零件表面质量提供了较好的借鉴与理论分析基础。     

Effect of Machining Parameters on Surface Integrity in High Speed Milling of Super Alloy GH4169/Inconel 718

Control of surface integrity is a vital consideration in the machining of components subjected to fatigue loading, for example, critical components of aerospace engines. In this research, three important aspects of surface integrity of a machined part—surface roughness, micro-hardness, and residual stresses—were analyzed for their variations with the cutting parameters. Finish milling of super alloy GH4169/Inconel 718 was carried out using coated cemented carbide and whisker-reinforced coated ceramic inserts. All of the three machining parameters—cutting speed, feed rate, and depth of cut—were found to have a substantial effect on the surface integrity of the finished part. Although different cutting parameters gave different effects for the two types of cutting inserts, overall better surface integrity was obtained at minimum cutting feed and medium cutting speed and depth of cut value. Moreover, carbide inserts produced better surface integrity of the finished part, whereas ceramic inserts generated very high surface tensile stresses and poor surface finish due to back striking of the adhered metal chips.     

Surface Roughness Investigation in the Hard Turning of Steel Using Ceramic Tools

The present work evaluates the use of conventional and multi-radii ceramic tools in the turning of AISI H13 in terms of surface quality. The selected design factors are the cutting speed, feed rate, and type of tool. To carry out this research, a design of experiments was used. The obtained results were analyzed using the analysis of variance (ANOVA), which allowed recognition of the influence of the feed rate and type of tool on the surface quality. By contrast, the cutting speed was found to be a factor that had no statistical significance. When comparing the experimental with the theoretical values, the results of the conventional and multi-radii tools were found to differ. In addition, it was highlighted that the feed rate has an important influence on the difference between the experimental and theoretical results.     

钛合金立铣表面粗糙度预测新方法

为实现加工前对表面粗糙度的预测,建立高精度的表面粗糙度预测模型至关重要.针对钛合金立铣表面粗糙度的特点及传统预测方法的不足,提出了表面粗糙度预测新方法.分别用递推最小二乘算法、基本蚁群算法与混合蚁群算法训练模糊系统,混合蚁群算法的收敛效果优于递推最小二乘算法和基本蚁群算法.通过回归分析建立了表面粗糙度的两种经验公式.对各方法所得模型进行测试,结果表明混合蚁群算法训练模糊系统的预测效果优于其他方法,用混合蚁群算法训练的模糊系统进行表面粗糙度预测是可行的.     

Diffusion Bonding of Laser Surface Melted Nickel Alloy Material

Diffusion bonding studies were performed on Laser Surface Melted (LSM) Ni-Cr-Fe material. LSM generates metastable microstructures with extended solid solution. The rapid quenching associated with LSM generates a zone that is void of intragranular precipitates, consists of well-defined grain boundaries via intergranular carbides, and contains fine-grained material. Grain growth across the bondlineand precipitate morphology were studied as a function of laser beam power (energy density) and bonding temperature. LSM at low energy density produced excellent grain growth across the bondline even when bonding at low temperature.     

GH4169高温合金化学铣切表面粗糙度的影响因素

为了满足生产对GH4169高温合金化学铣切加工表面粗糙度的要求,通过单因素试验研究了化铣液的主要成分和化铣工艺参数对GH4169高温合金表面粗糙度的影响。结果表明:随着化铣液中FeCl3和HNO3浓度的升高,表面粗糙度呈下降趋势;当化铣液温度高于50℃时,表面粗糙度在1.4μm以下;HCl,HF浓度均为200 mL/L时,表面粗糙度最小;添加剂SA和SN能够降低表面粗糙度和消除凹槽;随着化铣液中Ni2+浓度的增加,表面粗糙度也随之变大,当Ni2+浓度大于26.95 g/L时,表面粗糙度达到1.6μm以上,不符合加工要求;最佳化铣工艺为200～250 g/L FeCl3,200 mL/L HF,150 mL/L HNO3,200 mL/L HCl,0.2 g/L添加剂SA,0.5 mL/L添加剂SN,温度53℃,该工艺下化铣的GH4169高温合金表面质量良好,无凹槽、沟蚀,表面光洁,粗糙度小于1.6μm,符合生产要求。     

航空钛合金板胶接表面粗糙度的超声测量

采用一种新的超声频谱法快速测量航空钛合金板经喷砂预处理后的胶接表面粗糙度,并引入表面面积均方根粗糙度系数ST来表征材料表面三维微观形貌.以航空Ti-6Al-4V钛合金胶接板为测量试样,超声换能器接收测试试样表面的反射回波,并计算得到AR参数谱.以反射脉冲AR参数谱和声波镜面反射理论为基础,建立了有关脉冲波声反射系数和表面均方根粗糙度系数ST的数学模型.利用表面粗糙度系数理论模型.数值计算反射回波的理论频谱曲线,并与实测反射回波AR谱进行拟合.利用最小值搜索算法,处于最佳拟合时的表面粗糙度系数ST即为试样胶接表面的测量结果.实验表明,超声反射频谱法测量结果与轮廓仪测量结果符合得很好,该测量方法在材料或零部件表面粗糙度在线测量中具有广泛的应用前景.     

航空钛合金板胶接表面粗糙度的超声测量

采用一种新的超声频谱法快速测量航空钛合金板经喷砂预处理后的胶接表面粗糙度,并引入表面面积均方根粗糙度系数Sr来表征材料表面三维微观形貌．以航空Ti-6Al—4V钛合金胶接板为测量试样,超声换能器接收测试试样表面的反射回波,并计算得到AR参数谱．以反射脉冲AR参数谱和声波镜面反射理论为基础,建立了有关脉冲波声反射系数和表面均方根粗糙度系数Sr的数学模型．利用表面粗糙度系数理论模型．数值计算反射回波的理论频谱曲线,并与实测反射回波AR谱进行拟合．利用最小值搜索算法,处于最佳拟合时的表面粗糙度系数Sr即为试样胶接表面的测量结果．实验表明,超声反射频谱法测量结果与轮廓仪测量结果符合得很好,该测量方法在材料或零部件表面粗糙度在线测量中具有广泛的应用前景．     

Experimental Investigation to Optimize Tool Life and Surface Roughness in Inconel 718 Machining

In addition to the cutting conditions, the surface quality is also affected significantly by a worn tool in machining processes. Identification of the desirable tool life so that the surface quality is maintained within a desirable level is an essential task, especially in the machining of hard materials. In this paper, an optimal tool life and surface quality were identified in the turning operation of Inconel 718 Superalloy by means of experimental investigations and intelligent methods. First, the effect of machining time (MT) at the different cutting parameters was widely investigated on the surface roughness using the neural network model. Then, the modified Non-dominated Sorting Genetic Algorithm (NSGA) was implemented to optimize tool life and surface roughness. For this purpose, a new approach was implemented and the MT was taken into account as the input and output parameters during the optimization. Finally, the results of optimization were classified and the suitable states of the machining outputs were found. The results indicate that the implemented strategy in this paper provides an efficient approach to determine a desirable criterion for tool life estimation in machining processes.     

Optimizing the Machining Parameters for Minimum Surface Roughness in Turning of GFRP Composites Using Design of Experiments

In recent years, glass fiber reinforced plastics (GFRP) are being extensively used in variety of engineering applications in many different fields such as aerospace, oil, gas and process industries. However, the users of FRP are facing difficulties to machine it, because of fiber delamination, fiber pull out, short tool life, matrix debonding, burning and formation of powder like chips. The present investigation focuses on the optimization of machining parameters for surface roughness of glass fiber reinforced plastics (GFRP) using design of experiments (DoE). The machining parameters considered were speed, feed, depth of cut and workpiece (fiber orientation). An attempt was made to analyse the influence of factors and their interactions during machining. The results of the present study gives the optimal combination of machining parameters and this will help to improve the machining requirements of GFRP composites.     

Vibration-Assisted Precision Machining of Steel with PCD Tools

This article presents experimental results of precision machining of steel alloys with polycrystalline diamond tools. Ultrasonic vibration-assisted cutting was tried out for expanding the application of diamond tools for high-precision and high-quality machining of ferrous materials. The experimental results show that compared with conventional turning, the cutting performance, in terms of cutting force, surface finish, and tool life, was improved by applying ultrasonic vibration to the cutting tool. The cutting forces and tool wear measured in vibration cutting are much lower than those in conventional cutting. The tool wear mechanism was discussed on the basis of the observation of wear zone.     

表面粗糙度的光学测量方法

表面粗糙度的光学测量方法，具有非接触、精度高和响应快等优点，致使研究十分引人注目，发展极快。本文简单介绍了几种典型的光学测量原理和方法及一些商品化的仪器。     

表面粗糙度参数的计算方法

介绍了表面粗糙度参数的计算方法，并用ＱｕｉｃｋＢＡＳＩＣ语文编程实现。     

Intereference Correlator for Measuring Surface Roughness

Abstract

A correlation method for measuring surface roughness is proposed that is based on measurement of the transverse coherence function. The method can be applied to measure both roughness height and pitch. A device is designed that utilizes the method. The lower limit of height measurement is 0·005μm. The method is also applicable to dynamic and disperse systems.     

铝合金表面预处理及其镀镍工艺优化

本实验分别采用打磨、混合碱处理、水合肼处理和电晕处理四种方式对AA5052铝合金基体表面进行预处理,探讨了预处理方式对铝合金表面润湿性和表面形貌的影响,并在此基础上对铝合金表面镀镍工艺参数进行优化。通过接触角仪和扫描电子显微镜对镀层润湿性以及表面形貌进行表征,得到最佳化学镀镍条件:镀液温度为75℃,镀液pH值在6.2~6.4之间,化学镀时间40min。通过循环伏安法(CV)探索得到了最佳电化学镀镍条件:电镀时间为240s,电流密度为5mA/cm2,镀液温度为60℃。实验表明,该实验条件下可以得到理想的镍镀层,且该方法可以广泛应用于其他相关的材料研究领域。     

铝合金氧化电解着色技术

我厂已建成铝合金硬质氧化线多年 ,并一直采用有机染色 ,但由于有机染色法本身存在固有的缺陷 ,使我厂产品在质量上很难有较大的提高 ,现在这个问题已得到解决。小结如下 :铝、铝合金在氧化液中氧化一段时间后 ,在其表面生成一层较厚且多孔的氧化膜 ,具有较大的电阻 ,在低电压的电解液中很难有着色反应 ,但这并不妨碍膜的生成和化学溶解 ,经短时间的氧化和溶解 ,主要是膜的溶解 ,这样原氧化膜较薄的孔底最先被电压击穿 ,这样就在孔里发生了电解着色反应 ,再由于孔的活性影响 ,克服了极化作用 ,保证了反应顺利进行。1　着色体系的选择常用镍…     

石墨烯微片表面沉积亚微米金属镍合金颗粒

目的 利用金属粒子对石墨烯表面进行金属改性,以改善其吸波特性、复合材料界面和润湿性等,并且在保证石墨烯与金属粒子本身的特性基础上,还能产生另外的协同效应。方法 采用水热法将亚微米级的Ni金属颗粒沉积在物理法剥离的石墨烯微片表面上,并采用XRD, EDS, SEM, TEM等测试手段进行改性复合粉体的微观表征。结果 预处理工艺可以大大优化改性效果,使金属颗粒沉积更加均匀;最佳水热工艺为水热180 ℃,反应2 h,石墨烯微片负载量为2.5 g/L;微观表征结果显示,实际沉积的金属颗粒为Ni-P合金,分散的Ni-P合金粒径约为200 nm,在沉积过程中可形成团聚的约2 μm金属颗粒堆积,并分布于石墨烯微片表面。结论 水热法可以成功地将镍颗粒均匀地沉积在石墨烯微片表面上,从而实现石墨烯表面的金属改性。