A model for cutting forces generated during machining with self-propelled rotary tools

In this paper, a force model for self-propelled rotary tool is presented. Conventional oblique cutting force predictions were reviewed and extended to predict the cutting forces generated during machining with the self-propelled rotary tools. The model presented is based on Oxley's analysis and was verified by cutting tests using a typical self-propelled tool. Good agreement was obtained between the predicted and the experimentally measured forces under a wide range of cutting conditions. The effect of different cutting conditions on the friction coefficient along the chip/tool interface and tool rake face normal force were also presented and discussed.     

A new thermomechanical model of cutting applied to turning operations. Part I. Theory

In this paper, an analytical approach is used to model the thermomechanical process of chip formation in a turning operation. In order to study the effects of the cutting edge geometry, it is important to analyse its global and local effects such as the chip flow direction, the cutting forces and the temperature distribution at the rake face. To take into account the real cutting edge geometry, the engaged part in cutting of the rounded nose is decomposed into a set of cutting edge elements. Thus each elementary chip produced by a straight cutting edge element, is obtained from an oblique cutting process. The fact that the local chip flow is imposed by the global chip movement is accounted for by considering appropriate interactions between adjacent chip elements. Consequently, a modified version of the oblique cutting model of Moufki et al. [Int. J. Mech. Sci. 42 (2000) 1205; Int. J. Mach. Tools Manufact. 44 (9) (2004) 971] is developed and applied to each cutting edge element in order to obtain the cutting forces and the temperature distributions along the rake face. The material characteristics such as strain rate sensitivity, strain hardening and thermal softening, the thermomechanical coupling and the inertia effects are taken into account in the modelling. The model can be used to predict the cutting forces, the global chip flow direction, the surface contact between chip and tool and the temperature distribution at the rake face which affects strongly the tool wear. Part II of this work consists in a parametric study where the effects of cutting conditions, cutting edge geometry, and friction at the tool–chip interface are investigated. The tendencies predicted by the model are also compared qualitatively with the experimental trends founded in the literature.     

Laser Cladding of an Al-11.7Wt%Si Alloy on ZM5 Magnesium Alloy to Enhance the Corrosion Resistance

MG and its alloys are widely used in aerospace andautomotive in industry.Its poor corrosion resistancerestricts application of Mg alloy.Laser cladding andlaser surface melting are advantageous processes forimprovement of the corrosion resistance of themagnesium alloy[1-2].In the present study,lasercladding of an Al-11.7Wt%Si alloy with two differentthickness on ZM5die cast alloy was performed withCC>2laser with different powder thickness.1.Experimental ProcedureDie cast plates of ZM5Mg a…     

The form error prediction in side wall machining considering tool deflection

In this research, an effective method for the form error prediction in side wall machining with a flat end mill is suggested. The form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. The developed model can predict the surface form error accurately about 300 times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.     

薄壁方管激光弯曲过程的模拟研究

薄壁方管激光弯曲是一种利用激光加热来实现构件的柔性成形技术。研究了薄壁方管激光弯曲有限元模拟中的型处理、单元技术、边界条件、动热源构建、材料热吸收系数的选择、边界条件与初始条件等关键技术的处理，实现了薄壁方管激光弯曲过程的有限元模拟，分析了其变形机理。     

航空材料的两种激光表面处理技术

针对航空材料的表面强化问题,分析了激光表面处理技术在航空材料上应用的发展现状.论述了两种类型激光表面处理技术的基本原理和国内外研究现状.分析了激光表面处理技术在航空材料上应用的发展方向.     

CO2激光焊接不锈钢光致等离子体动态特性分析

光致等离子体是CO2激光焊接中一个重要的物理现象，它与焊接的稳定性、焊接质量及能量利用率等都有密切的关系。利用高速摄像及光信号监测两种手段对等离子体的动态变化过程及其对焊接稳定性的影响进行了深入的研究。提出了等离子体的变化每个周期内分为四个阶段，而影响焊接稳定性的根本原因是等离子体在穿透与未穿透之间的波动。     

Direct laser fabrication of thin-walled metal parts under open-loop control

Direct laser fabrication (DLF) is an advanced manufacturing technology, which can build full density metal parts directly from CAD files without using any modules or tools. The investigation on the fabrication of thin-walled parts of nickel alloy using open-loop DLF process is introduced in this paper. The experimental setup consisted of a CO₂ laser, a 3-axis CNC table, a coaxial powder nozzle and a powder recycler. The 3D-CAD file of a thin-walled metal part was converted into the STL file format and imported into software HUST-RP to generate ‘pseudo-random’ scanning paths of laser beam. The influence of process parameters on the build height of thin-walled metal parts was studied by 1–10 layered single-bead stacks of nickel alloy. The result shows that the interference factors which affect the build height of thin-walled metal parts occur randomly during the process. For open-loop DLF process, thin-walled metal parts can achieve much better shape quality if the process parameters are suitable. Multilayer single-bead walls were built up with different scanning velocity to obtain the optimal process parameters of thin-walled parts of nickel alloy. It shows that thin walls of nickel alloy with uniform height can be built up layer by layer in a certain range of specific energy. However, it is difficult to control the build height of complex thin-walled metal parts in an accurate manner just using optimal parameters. A special coaxial powder nozzle was designed in this paper. In a certain range, the deposition thickness of the nozzle is nearly linearly increased with increase in the standoff distance between the powder focusing point of the nozzle and the deposition substrate. By means of the nozzle, a novel method to control the build height of thin-walled metal parts using open-loop DLF process was introduced. The difference in build height of a thin-walled part can be compensated automatically in one or several layers during the process. It is proved that the build height of a thin-walled metal part can be accurately controlled in theory using the nozzle. A complex single-bead part of nickel alloy whose geometry was designed to be the well-known Chinese ‘FU’ was fabricated and explained in this paper. The result shows that the shape quality of the sample is quite good, and actual build height of the sample is 53.54 mm while the designed value is 54 mm.     

A new thermomechanical model of cutting applied to turning operations. Part II. Parametric study

In Part I of this work, Molinari and Moufki [Int. J. Mach. Tools Manufact., this issue], an analytical model of three-dimensional cutting is developed for turning processes. To analyse the influences of cutting edge geometry on the chip formation process, global effects such as the chip flow direction and the cutting forces, and local effects such as the temperature distribution and the surface contact at the rake face have been investigated. In order to accede to local parameters, the engaged part in cutting of the rounded nose is decomposed into a set of cutting edge elements. Thus each elementary chip, produced by a straight cutting edge element, is obtained from an oblique cutting process defined by the corresponding undeformed chip section and the local cutting angles. The present approach takes into account the fact that for each cutting edge element the local chip flow is imposed by the global chip movement. The material characteristics such as strain rate sensitivity, strain hardening and thermal softening, the thermomechanical coupling and the inertia effects are considered in the modelling. A detailed parametric study is provided in this paper in order to analyse the effects of cutting speed, depth of cut, feed, nose radius and cutting angles on cutting forces, global chip flow direction and temperature distribution at the rake face. The influence of friction at the tool–chip interface is also discussed.     

Micro-end-milling of single-crystal silicon

Ductile-regime machining of silicon using micro-end-mill is almost impossible because of the brittle properties of silicon, crystal orientation effects, edge radius of the cutter and the hardness of tool materials. Micro-end-milling can potentially be used to create desired three dimensional (3D) free form surface features using the ductile machining technology for single-crystal silicon. There is still a lack of fundamental understanding of micro-end-milling of single-crystal silicon using diamond-coated tool, specifically basic understanding of material removal mechanism, cutting forces and machined surface integrity in micro-scale machining of silicon. In this paper, further research to understand the chip formation mechanism was conducted. An analysis was performed to discover how the chips are removed during the milling process. Brittle and ductile cutting regimes corresponding to machined surfaces and chips are discussed. Experiments have shown that single-crystal silicon can be ductile machined using micro-end-milling process. Forces generated when micro-end-milling single-crystal silicon are used to determine the performance of the milling process. Experimental results show that the dependence of the cutting force on the uncut chip thickness can be well described by a polynomial function order n. As cutting regime becomes more brittle, the cutting force has more complex function.