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Ferhat Hamza Hammoudi Abderazek Smata Lakhdar Djeddou Ferhat Ali Rıza Yıldız 《The International Journal of Advanced Manufacturing Technology》2018,98(5-8):1267-1285
Selection of tooling to perform specific operations like drilling and milling on ceramic materials using rotary ultrasonic machining process is an important aspect to meet stringent dimensions on workpiece as well as intended performance of tool. This phenomenon is more critical for micro rotary ultrasonic machining. In the present study, an effort was made to do micro drilling operation of Ø0.3 mm tool with varying geometry, having different wall thicknesses and abrasive grain sizes using design of experiments. The effect of tool-based parameters like grain size and wall thickness has been studied on axial cutting force, radial cutting force, tool wear, edge chipping area and taper. After examining axial and radial cutting forces, it has been concluded that lower wall thickness (80 μm) tool is good for drilling operation; and higher wall thickness (100 μm) tool is good for milling operation under same material removal rate conditions. It has been also investigated that lower wall thickness (80 μm) tool has less edge chipping area and less taper and can impart high drilling depth as compared to higher wall thickness (100 and 150 μm) tool. It is also concluded that lesser grain size (15 μm) tools are advantageous in terms of edge chipping area and cutting force for drilling and milling operations as compared to higher grain size (30, 35 and 45 μm) tool at constant material removal rate. Higher grain size tools have been broken at 1.13 mm3/h material removal rate conditions due to bad profile accuracy. But higher grain size tools have worked fairly well at less material removal rate condition. Higher grain size tools produced less wear. Tool wear was found minimum in higher wall thickness (100 μm) tool having higher abrasive grain size (30 μm). Using inferred results, Ø0.3 mm drilling experiments have been carried out on six aerospace ceramic materials. Also, groove of 0.5 mm size using Ø0.3 mm optimised tool has been successfully carried out in sintered SiC. 相似文献
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切削高硬度钢的 Al_2O_3-TiC 陶瓷刀具 总被引:3,自引:0,他引:3
采用热压方法制备了含有10%~50%TiC和不同粒度的Al2O3 TiC陶瓷刀具,研究了刀具的切削性能。试验表明,在车削合金工具钢时,TiC含量为20%~30%的微细晶粒陶瓷刀具具有优异的抗剥落性能和最佳的切削效果。 相似文献
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氧化铝陶瓷刀具材料具有硬度高、耐磨性好、高温性能优良、抗黏结和抗扩散能力强、化学稳定性好等特点,广泛应用于高速切削和切削难加工材料领域。从陶瓷材料晶粒尺寸与摩擦学性能相关性、复相氧化铝陶瓷材料的摩擦学性能和氧化铝陶瓷的磨损机制3个方面,综述氧化铝陶瓷材料摩擦学研究进展,以期为新型高品质氧化铝陶瓷刀具材料的开发提供帮助。细化晶粒和组分复合化是提高陶瓷材料的强度和断裂韧性,进而提升其摩擦学性能的有效途径,但目前氧化铝陶瓷摩擦学研究主要是基于晶粒尺寸为600 nm以上的单相陶瓷和基体晶粒尺寸为1μm左右的复相陶瓷材料,对纳米/超细晶(500 nm以下)氧化铝陶瓷材料的研究是未来的研究方向。 相似文献
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With wide applications of nickel-based superalloys in strategic fields, it has become increasingly necessary to evaluate the performance of different advanced cutting tools for machining such alloys. With a view to recommend a suitable cutting tool, the present work investigated various machinability characteristics of Incoloy 825 using an uncoated tool, chemical vapor deposition (CVD) of a bilayer of TiCN/Al2O3, and physical vapor deposition (PVD) of alternate layers of TiAlN/TiN-coated tools under varying machining conditions. The influence of cutting speed (51, 84, and 124 m/min) as well as feed (0.08, 0.14, and 0.2 mm/rev) was comparatively evaluated on surface roughness, cutting temperature, cutting force, coefficient of friction, chip thickness, and tool wear using different cutting tools. Although the CVD-coated tool was not useful in decreasing surface roughness and temperature, a significant reduction in cutting force and tool wear could be achieved with the same coated tool under a high cutting speed of 124 m/min. On the other hand, the PVD-coated tool outperformed the other tools in terms of machinability characteristics. This might be attributed to the excellent antifriction and antisticking property of TiN and good toughness due to the multilayer configuration in combination with a thermally resistant TiAlN phase. Adhesion, abrasion, edge chipping, and nose wear were the prominent wear mechanisms of the uncoated tool, followed by the CVD-coated tool. However, remarkable resistance to such wear was evident with the PVD TiAlN/TiN multilayer-coated tool. 相似文献
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We have proposed cutting tools with various textured surfaces to increase cutting tool life. Our previous studies have developed cutting tools having periodical stripe-grooved surfaces on their rake face formed using femtosecond laser technology, which displayed high crater wear resistance in cutting of steel materials. In this study, the mechanism for suppressing the crater wear on the tool surface and the relationship between texture dimensions and wear resistance were investigated to provide a guideline for developing tools with textured surfaces. Furthermore, we newly introduced the textured surfaces into a flank face of cutting tools to improve flank wear resistance. Face milling experiments on steel materials exhibited that the newly developed tool having the textured flank face significantly reduced the flank wear. Moreover, the influences of texture dimensions and cutting conditions on the flank wear resistance were also discussed. 相似文献
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Cutting tests were performed using ceramic cutting tools under continuous cutting conditions. The tests were carried out on AISI 1040 steel, with cutting speeds ranging from 5 to 11 m s−1. The wear mechanism was investigated for both crater and flank. Alumina-toughened zirconia of submicron grain size showed the best wear resistance. Alumina with TiC, TiN and ZrO2 inclusions exhibited a wear resistance a little lower than the above-mentioned materials. Low chemical stability seems to be the reason for the poor performances of the silicon carbide whiskers-reinforced alumina, silicon nitride and the tungsten carbide inserts. 相似文献
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微细加工中的微型铣床、微刀具磨损及切削力的实验研究 总被引:2,自引:0,他引:2
由于微机电系统(Micro Electro Mechanical System,MEMS)在微小零件加工中存在不足,微细铣削加工作为一项补充技术正在日益受到人们的重视。介绍了研制的微型精密三轴联动立式铣床(300 mm×300 mm×290 mm)的系统构成,开发了中文控制软件并集成了视频采集系统,此设备在薄膜型工件(膜厚65 μm)的微槽加工中取得了满意的效果(膜厚方向上材料去除率90.7%,成品率大于80%)。对微径端铣刀进行了力学特性分析,并通过刀具磨损试验分析了微径硬质合金TiA1N涂层及非涂层铣刀的磨损机理。最后通过槽铣硬铝2A12的试验研究了切削用量(主轴转速、背吃刀量和每齿进给量)对微细铣削力的影响,为微细铣削切削机理的深入研究奠定了基础。 相似文献
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对TiB2颗粒增强Al2O3刀具在车削正火态、调质态45#钢和球墨铸铁齿轮坯时的刀具磨损性能、磨损机理进行了研究,并与硬质合金刀具的耐磨性能进行了对比。结果表明:Al2O3┐TiB2陶瓷刀具具有良好的耐磨性能。刀具磨损主要以脆性剥离为主,同时存在着犁耕和塑性流变过程,陶瓷刀具表面形成的粘结层结构疏松,与基体结合力较弱,较易脱落,不易形成粘结磨损。 相似文献
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The machining performance of monolithic and composite silicon nitride and Al2O3-based cutting tools in continuous turning of Inconel 718 was examined. The character of tool wear has been found to vary, depending on the feed rate and cutting speeds. At a lower cutting speed, of 120 m/min, tool life is restricted by depth-of-cut notching, while at high cutting speeds (300 m/min), tools fail due to nose wear and fracture. The sensitivity of monolithic Si3N4 and Al2O3 to depth-of-cut notching was found to he significantly reduced with the addition of SiC whiskers, and to a lesser extent with TiC particulates. The ceramic composites also exhibited resistance to nose and flank wear that was higher than that of the monoliths. The internal stress distribution for the cutting tool has been calculated using the finite element method and is the basis for explaining fracture beneath the rake face. Cutting tool wear results are discussed in terms of chemical and mechanical properties of the ceramic tool material, abrasive wear, thermal shock resistance, and metal cutting conditions. 相似文献
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实验分析了硬脆材料旋转超声磨削过程中刀具结合剂类型对加工性能的影响以便提高加工精度和加工表面的完整性.首先,采用能谱分析研究了铁基、陶瓷基和青铜基3种超声振动刀具中结合剂与金刚石颗粒的把持形式,并根据相同加工工艺条件下刀具磨损形式确定了把持力大小.然后,结合超声振动刀具特性,通过旋转超声磨削加工实验研究刀具结合剂类型与切削力、刀具磨损量、加工表面完整性的关系,并对实验结果进行了分析.实验结果表明:相对于陶瓷基和青铜基结合剂超声振动刀具,铁基结合剂超声振动刀具把持力最大,Z轴切削力平均值最小(为46.8 N);加工18 000 mm3材料后,刀具轴向磨损量最小(为0.1 mm);而陶瓷基结合剂超声振动刀具加工表面质量最好,表面粗糙度最大值为21.79 μm.结果证实铁基超声振动刀具适用于粗加工,陶瓷基超声振动刀具则适用于精加工. 相似文献
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H.A. Kishawy Lei Pang M. Balazinski 《International Journal of Mechanical Sciences》2011,53(11):1015-1021
In this paper, an attempt is made to evaluate the self-propelled rotary carbide tool performance during machining hardened steel. Although several models were developed and used to evaluate the tool wear in conventional tools, there were no attempts in open literature for modeling the progress of tool wear when using the self-propelled rotary tools. Flank wear model for self-propelled rotary cutting tools is developed based on the work-tool geometric interaction and the empirical function. A set of cutting tests were carried out on the AISI 4340 steel with hardness of 54–56 HRC under different cutting speeds and feeds. The progress of tool wear was recorded under different interval of time. A genetic algorithm was developed to identify the constants in the proposed model. The comparison of measured and predicted flank wear showed that the developed model is capable of predicting the rate of rotary tool flank wear progression. 相似文献
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Domenico Umbrello 《The International Journal of Advanced Manufacturing Technology》2013,69(9-12):2183-2190
Machining of advanced aerospace materials have grown in the recent years although the diffucult-to-machine characteristics of alloys like titanium or nickel-based alloys cause higher cutting forces, rapid tool wear, and more heat generation. Therefore, machining with the use of cooling lubricants is usually carried out. To reduce the production costs and to make the processes environmentally safe, the goal is to move toward dry cutting by eliminating cutting fluids. This objective can be achieved by using coated tool, by increasing cutting speed, and by improving the product performance in term of surface integrity and product quality. The paper addresses the effects of cutting speed and feed on the surface integrity during dry machining of Inconel 718 alloy using coated tools. In particular, the influence of the cutting conditions on surface roughness, affected layer, microhardness, grain size, and microstructural alteration was investigated. Results show that cutting conditions have a significant effect on the parameters related to the surface integrity of the product affecting its overall performance. 相似文献
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为深入研究微织构排列形式对微织构理刀具的抗磨减摩机理的影响,分别从理论、仿真及试验等方面对最优的微织构排布形式进行研究。首先,建立微织构在刀具前刀面的数学模型及仿真模型。其次,通过试验验证仿真结果的准确性。仿真及试验研究均发现,变密度微织构球头铣刀的铣削性能优于均匀分布密度的微织构球头铣刀。最后,运用模糊评价法优选最优的铣削性能的微织构球头铣刀,优化结果表明,两排织构间距先为200 μm,再为150 μm,最后为175 μm的微织构球头铣刀的铣削性能最好。该项研究使刀具具有良好的抗磨减磨性,提高加工效率及被加工工件的表面质量。 相似文献
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梯度功能陶瓷刀具切削淬硬钢的研究 总被引:8,自引:1,他引:8
在国内首先研制成功梯度功能陶瓷刀具材料FG-1,并研究了该刀具车削淬硬工具钢T10A的切削性能及耐磨性。结果表明,FG-1具备优异的物理力学性能:在低速切削条件下,FG-1与普通陶瓷刀具LT55及SG-4的耐磨性相差不大;而随着切削速度的提高,FG-1的性能明显优于LT55和SG-4刀具。其原因是刀具材料成分的梯度组成发挥了缓解热应力的作用。 相似文献
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利用电弧法沉积制备Al Cr N、Al Cr Si N、Al Cr N/Ti Al N、Al Cr N/Ti Si N四种用于钛合金切削加工涂层,研究了涂层的基本特性及切削使用效果。结果表明,Al Cr N涂层呈柱状生长,通过添加Si等元素或采用多层交替沉积有利于形成细化晶粒组织,提升涂层纳米硬度。切削试验表明,在低速铣削钛合金TC4时,Al Cr N/Ti Al N复合涂层表现最好。在较高速铣削时,四种涂层的刀具表现性能接近。 相似文献
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Guangming Zheng Jun Zhao Yonghui Zhou Anhai Li Xiaobin Cui Xianhua Tian 《The International Journal of Advanced Manufacturing Technology》2013,67(9-12):2799-2810
The cutting performance, failure types, and mechanisms of the graded nano-composite ceramic tools were investigated during dry face milling of Inconel 718. In these tests, round ceramic inserts were used at cutting speeds ranging from 500 to 1,100 m/min. The structures of the chips, cutting forces, and surface roughness were also examined. Failure surfaces of the tools were characterized by scanning electron microscopy. The results showed that the graded tool possessed a self-sharpening characteristic and exhibited higher cutting performance compared with the homogeneous ones, as a result of its enhanced mechanical properties, higher abrasive wear, and fracture resistance. The failure mechanisms of the tools involved chipping, flaking, notch wear, abrasive wear, and adhesive wear. The mechanisms responsible for the higher cutting performance of the graded tools were inferred to be the formation of compressive residual stress in the surface layer induced by the graded compositional structure. 相似文献