基于间歇性车削加工过程中刀具状态实时检测的研究

针对间歇性切削过程中刀具受间歇性冲击导致的损坏,基于一种新的信号处理方法提出一种用于在线预测刀具切削过程中刀具状态监测方法。该方法基于希尔伯特黄变换(HHT)和Taer-Kaiser能量算符(TKEO),不依赖于切削参数和工件材料对预失效阶段的非稳定裂纹拓展特性进行识别。对刀具状态与切削参数和工件材料参数之间的相关性加以分析并用于保护加工表面。通过实验对监测系统的有效性进行验证,能够保证在刀具损坏之前停止机床操作,验证了该系统的准确性。     

An investigation of laser-assisted machining of Al2O3 ceramics planing

Laser-assisted machining (LAM), an alternative method of fabricating difficult-to-machine materials, uses primarily laser power to heat the local area (without necessarily evaporating or melting any material) before the material is removed. It not only efficiently reduces the cutting force during the manufacturing process but also improves the machining characteristics and geography with regard to difficult-to-machine materials, especially structural ceramics.This study on the application of laser-assisted machining to Al₂O₃ ceramics examines the measurements of cutting force and workpiece surface temperature as well as surface integrity and tool wear. Specifically, it uses the lattice Boltzmann method (LBM) to calculate the temperature distribution inside the ceramic workpiece during the LAM process and ensure that the laser energy causes no subsurface damage. The experimental results reveal that the LAM process efficiently reduces the cutting force by 22% (feed force) and 20% (thrust force) and produces better workpiece surface quality than conventional planing.     

Laser Cutting of Multilayered Kevlar Plates

Laser cutting of Kevlar plates, consisting of multilayered laminates, with different thicknesses are carried out. A mathematical model is developed to predict the kerf width, thermal efficiency, and specific energy requirements during cutting. Optical microscopy and Scanning Electron Microscopy (SEM) are employed to obtain the micrographs of the cutting sections. The kerf width size is measured and compared with the predictions. A factorial analysis is carried out to assess the affecting parameters on the mean kerf width and dimensionless damage sizes. It is found that the kerf width and damage sizes changes sharply when increasing cutting speed from 0.03 to 0.08 m/s. Thermal efficiency of the cutting process increases with increasing thickness and cutting speed while specific energy reduces with increasing thickness. The main effects of cutting parameters are found to be significant on the mean kerf width and dimensionless damage sizes, which is more pronounced for the workpiece bottom surface, where locally distributed char formation and sideways burning are observed.     

Simulation of cutting process in peripheral milling by predictive cutting force model based on minimum cutting energy

The cutting force and the chip flow direction in peripheral milling are predicted by a predictive force model based on the minimum cutting energy. The chip flow model in milling is made by piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities. The cutting edges are divided into discrete segments and the shear plane cutting models are made on the segments in the chip flow model. In the peripheral milling, the shear plane in the cutting model cannot be completely made when the cutting point is near the workpiece surface. When the shear plane is restricted by the workpiece surface, the cutting energy is estimated taking into account the restricted length of the shear plane. The chip flow angle is determined so as to minimize the cutting energy. Then, the cutting force is predicted in the determined chip flow model corresponding to the workpiece shape. The cutting processes in the traverse and the contour millings are simulated as practical operations and the predicted cutting forces verified in comparison with the measured ones. Because the presented model determines the chip flow angle based on the cutting energy, the change in the chip flow angle can be predicted with the cutting model.     

干式切削20Cr表面粗糙度和残余应力研究

针对低渗碳钢20Cr材料制作齿轮轴等零件表面质量要求,如表面粗糙度低于1.6μm,零件表面耐疲劳性能良好。试验采用干式切削20Cr钢材方式,在背吃刀量固定的工序中,研究切削速度和进给量对20Cr材料表面粗糙度的影响,同时结合有限元技术,分析切削速度和进给量对20Cr表面残余应力的影响。干式切削试验采用单因素方法,进行多组干式切削20Cr工件,对比分析各组工件表面粗糙度,结果表明当进给量较小时,切削速度对工件表面粗糙度有显著影响,表现为表面粗糙度随切削速度增加而变大;当切削速度一定时,进给量增加导致表面粗糙度变大,并且进给量对表面粗糙度的影响大于切削速度;对于工件表面残余应力,增加切削速度和进给量均导致残余应力变大,因而较小的切削速度和进给量可以降低工件表面残余应力,改善应力分布状态。     

基于分子动力学的金属钛纳米切削过程研究

本文采用基于分子动力学的仿真方法建立了金属钛纳米切削分子动力学模型,选择了有代表性的切削条件,通过仿真得到瞬间原子位置图像并对切削过程中材料去除现象、加工表面形成过程、系统势能和工件温度等的变化进行了分析。发现在金属钛的纳米切削过程中切屑和加工表面是由于晶格能的释放和位错的不断延伸扩展形成的。已加工表面原子的弹性恢复和晶格重构能够减缓总势能和温度不断增加的趋势,并使其伴随有微小波动。     

Estimation of the specific cutting pressures for mechanistic cutting force models

This paper presents a new method for the estimation of specific cutting pressures for mechanistic cutting force models for the face milling process. Traditional methods for the estimation of specific cutting pressures require calibration tests using a single cutting insert on a workpiece which has no surface discontinuities. However, face milling operations in the industry are typically performed on workpieces that have workpiece surface discontinuities and using a large number of cutting inserts to enhance productivity. The performance of calibration tests to determine specific cutting pressures is usually very expensive. Hence, a new method to estimate specific cutting pressures directly from cutting force data collected during actual production is developed. The results obtained using the traditional and the new method are validated through simulations and experimental tests.     

Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351)

In the present contribution, numerical and experimental methodologies concerning orthogonal cutting are proposed in order to study the dry cutting of an aeronautic aluminium alloy (A2024-T351). The global aim concerns the comprehension of physical phenomena accompanying chip formation according to cutting velocity variation.For the numerical model, material behaviour and its failure criterion are based on the Johnson–Cook law. The model proposes a coupling between material damage evolution and its fracture energy. A high-speed camera was used to capture the chip formation sequences. The numerical results show that the chip–workpiece contact and the tool advancement induce bending loads on the chip. Consequently, a fragmentation phenomenon takes place above the rake face when the chip begins to curl up. The computed results corroborate with experimental ones. The numerical results predict the residual stress distribution and show high values, along the cutting direction, on the machined workpiece surface.     

Production of integral serrated outside finned tube using a combined method of rolling and wedging/extruding

Most recently, energy and materials savings considerations have stimulated the demand for high efficient and compact heat exchangers. Finned tube is a well-known technology that promotes heat transfer efficiency. This paper proposes a new method of manufacturing integral serrated outside finned tube—rolling and wedging/extruding method. In this method, surface material of workpiece is only split from workpiece body, but not removed. The split and inseparate “chips” can be used to integral outside fins. The wedging/extruding tool is designed. Comparing to conventional cutting tool, the secondary cutting edge is transformed into curve face and only primary cutting edge is remained in wedging/extruding tool. The forming process of integral serrated outside finned tube by rolling and wedging/extruding is analyzed. In addition, the main technical parameters which affect the fins height and pitch are also discussed.     

Review on ultrasonic machining

Ultrasonic machining is of particular interest for the cutting of non-conductive, brittle workpiece materials such as engineering ceramics. Unlike other non-traditional processes such as laser beam, and electrical discharge machining, etc., ultrasonic machining does not thermally damage the workpiece or appear to introduce significant levels of residual stress, which is important for the survival of brittle materials in service. The fundamental principles of ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate and workpiece accuracy are reviewed, with particular emphasis on the machining of engineering ceramics. The problems of producing complex 3-D shapes in ceramics are outlined.     

On the influence of gamma prime upon machining of advanced nickel based superalloy

Whilst gamma prime (γ′) phase is the strengthening phase in Ni-based superalloys its influence on machining has been seldom investigated. This paper reports for the first time on the effect of γ′ upon machining of Ni-based superalloys when cutting with parameters yielding different cutting temperature intervals which lead to strengthening/softening effects on the workpiece (sub)surface. In-depth XRD, SEM/FIB, EBSD analysis and unique micro-pillar testing in the workpiece superficial layers indicated that with the increase of γ′ fraction the grain plastic deformation significantly decreased, while specific cutting energy can switch from low to high values influenced by the real cutting temperature.     

Experimental investigation and simulation of machining thin-walled workpieces

An enhanced simulation model is presented in this paper to predict form deviations in end milling processes of thin-walled structures. The calculation of tool engagement is based on level curves representing surface geometry of the workpiece and the NC code driven sweep volume. To consider influences of force-induced deflections resulting in static form errors on machined surface of the workpiece, a model for superposed stresses is enclosed. Derived from the tool engagement, the cutting force is predicted using a parametric force model. The experimental investigations within the measuring of static and dynamic form errors during processing and afterwards are shown and measurement results are compared with results of the cutting simulation to verify the proposed method. The presented achievements are deduced from research activities aiming at an increased understanding of shape deviation induced by interactions between tool, workpiece and clamping device during machining.     

A review of cutting fluid application in the grinding process

It is generally accepted that heat generation is the limiting factor in the grinding process due to the thermal damage associated with it. To combat this energy transfer, a cutting fluid is often applied to the operation. These cutting fluids remove or limit the amount of energy transferred to the workpiece through debris flushing, lubrication and the cooling effects of the liquid. There have been many new and exciting systems developed for cutting fluid application in the grinding process. This paper reviews some of the common as well as some of the more obscure cutting fluid systems that have been employed in recent years with an emphasis on creep-feed applications. The review also suggests possible avenues of future research in cutting fluid application for the grinding process.     

表面微织构在切削过程中的研究进展

在切削过程中,临近切削刃的刀具前刀面与切屑、刀具后刀面与已加工表面接触区存在的高温高压情况严重影响了刀具服役寿命和工件表面完整性。表面微织构技术是一种先进的表面改性技术,在刀具表面制备不同尺寸参数、形状参数、分布参数的表面织构能够显著影响刀具的切削性能。当刀具表面微织构制备方法不同时,微织构所呈现的性能也不同。首先从制备技术的原理、制备过程、制备技术特点等方面对当前最先进的刀具表面微织构制备技术进行了综述。然后从切削力、切削温度、刀具磨损、切屑形成、工件表面完整性等角度分析了微织构对刀具切削性能的影响规律与机理。在分析切削力、切削温度、刀具磨损、切屑形成等4个指标时重点关注了刀具前刀面微织构所起的作用,在分析工件表面质量时,同时考虑了刀具后刀面微织构、前刀面微织构的影响。最后,介绍了当前微织构的研究热点,主要包括微织构技术与钝化刃口、润滑剂的协同作用对切削性能的影响,以及微织构刀具在切削过程中发生的衍生切削行为。通过对文献的归纳、总结与深入分析,给出了表面微织构未来的研究方向,为刀具进一步优化提供设计参考。     

薄壁筒车削颤振稳定性预测

切削颤振是制约薄壁筒工件加工质量和效率的主要因素之一。采用半离散法对含有时滞项的动力学方程进行稳定性预测分析,结合薄壁筒工件切削振动试验,研究刀具、工件动力学参数匹配关系变化对切削加工稳定性的影响。通过仿真分析得出:随着刀具刚度或固有频率的提升,切削系统稳定性呈上升趋势,但过度提升刀具刚度并不会有效提升切削稳定性;在刀具与工件固有频率接近处,切削系统的稳定性较差;适当调整刀具动态特性参数有利于提高柔性工件切削加工的稳定性;切削过程中,时变的切削位置和工件尺寸会引起切削系统动态特性的变化。根据时变稳定性预测图,从稳定性分析角度解释了一次走刀切削试验中薄壁筒工件表面出现不同加工形貌的原因。     

石墨烯纳米流体加工Ti-6Al-4V合金的黏着磨损、表面粗糙度和切削力

提出了一种基于石墨烯纳米颗粒分散在菜籽油中的切削液为加工区域提供润滑/冷却的新加工方式,确定了该纳米流体对刀具切屑粘附层的影响。与干切削相比,使用菜籽油+石墨烯加工后的刀面和前刀面的切屑粘附层厚度分别降低了38.8%和28.8%,切削力降低51.4%,工件表面粗糙度降低50.1%。石墨烯较高的导热系数可以降低切割区域的温度。此外,石墨烯可以渗透到刀具与工件之间的接触区域,有效地保护了刀具的涂层材料,减少了粘附在工件表面的切屑,并且填充了工件表面形成的凹坑,从而提升了表面质量。     

On cutter deflection surface errors in peripheral milling

Cutter deflections induce significant amount of surface error on machined components and it is one of the major obstacles towards achieving higher productivity in peripheral milling operation. These surface errors do not take one particular form and their shape and profile measured along axial direction, varies significantly with cutting conditions. The understanding and characterization of all possible surface error types is of immense value to process planners as it forms a basis for controlling and compensating them. This paper presents a methodology to classify surface error profiles and to relate the same with cutting conditions in terms of axial and radial engagement between cutter and workpiece. The proposed characterization scheme has been validated using computational studies and machining experiments. The importance of proposed characterization is further demonstrated in understanding peripheral milling of curved geometries where workpiece curvature influences radial engagement of the cutter that often changes surface error shape both qualitatively and quantitatively. Computational and experimental studies undertaken to study machining of curved geometries underline the importance of proposed characterization scheme in identifying correct cutting conditions for a given machining situation.     

Correlating surface roughness and vibration on plunge cylindrical grinding of steel

Since the wear of a grinding wheel has a direct effect on the workpiece vibration and both have effect on the workpiece quality, the main goal of this work is to study the relation between the process vibration signals and the workpiece quality (mean roughness, circularity and burning) as the grinding wheel gets worn, in an attempt to use these signals to decide the exact moment to dress the wheel. In order to reach this goal, several experiments were carried out in a plunge cylindrical grinding operation of an AISI 52100 quenched and tempered steel, having as input variables the dressing overlap ratio, the spark out time and the workpiece velocity. The output variables were the workpiece surface roughness and circularity and also the process vibration during both, the cutting phase and the spark out phase of the grinding cycle. The main conclusions were: (1) it is possible to have good workpiece quality even with a vibration level much higher than that obtained with a recently dressed wheel; (2) vibration during cutting phase and at the end of complete spark out can be used to monitor the wheel condition at least when high dressing overlap ratio is used; and (3) the decrease in the spark out time makes the vibration at the end of spark out increase a lot, but does not cause such a damage in surface roughness. This fact makes the use of partial spark out feasible in some situations.     

面向绿色高表面质量制造的硬态车削工艺多目标参数优化

目的 为了进行硬态车削绿色制造与工艺性能协同优化研究,提出一种同时考虑碳排放量和表面粗糙度的多目标优化方法。方法 首先,通过分析硬态车削过程中切削参数、工件材料、刀具材料等因素对切削功率的影响建立碳排放目标函数,针对工件的表面粗糙度受到切削条件、工件材料、刀具材料等诸多因素的影响,利用正交试验和广义回归神经网络建立轴承硬态车削表面粗糙度目标函数。然后,考虑加工过程中机床特性和硬车实际工况等约束条件,建立以切削参数为优化变量,以碳排放量和表面粗糙度为优化目标的多目标优化模型,引入权重系数将其转化为单目标优化模型。最后,利用遗传算法对优化模型进行优化求解,深入分析切削参数对优化目标的影响。结果 在工厂实际轴承产品硬车试验中验证了优化模型的有效性,结果表明,切削速度为225 m/min、进给量为0.08 mm/r、背吃刀量为0.10 mm时,碳排放量和表面粗糙度的综合优化指标最低。相比优化前,虽然碳排放量上升了13.05%,但表面质量提升了34.44%。结论 研究结果对面向绿色制造的轴承硬车工艺参数优化提供理论方法有重要意义。     

An approach to use an array of three acoustic emission sensors to locate uneven events in machining—Part 1: method and validation

The paper reports on an approach to use the triangulation technique applied to arrays of acoustic emission sensors for the location of uneven events occurring during machining. The generation of some uneven events (e.g. workpiece surface discontinuities, plucking, smearing) in machining can be associated with the release of acoustic emission energy. When more than one cutting edge is in contact with the workpiece (e.g. broaching, milling) it is difficult to associate the burst of acoustic emission signal with the tooth that generated it and therefore to locate, relatively to the workpiece surface, the position of acoustic source. The location of the acoustic source, related to the occurrence of the uneven event, is evaluated by feeding the time delays in detecting the same burst signal by three acoustic sensors placed on the workpiece, into an analytical geometry model. Using numerical methods in Matlab, the analytical solution for the location of acoustic source was found by adding to the system formed by three spherical analytical equations, with the acoustic emission sensors as their centres, the characteristics of the cutting tool path. The methodology has been calibrated using pencil break lead tests to asses the accuracy of the acoustic source location and the requirements of the data acquisition system. ‘Near-orthogonal’ cutting trials were carried out using two different arrays of acoustic emission sensors and the uneven events located relatively to the workpiece surface. It was found that the proposed methodology has potential to locate, at a reasonable accuracy, the acoustic sources that are related to the occurrence of uneven events in machining. This work represents a preliminary investigation to be used for the location of workpiece defects during machining with multiple cutting edge tools.