高强度钢干式铣削替代半精磨的试验研究

采用硬质合金刀片(YW1)和涂层刀片(YB415)进行了高强度钢的干式铣削代替半精磨试验研究。根据试验结果,确定适合加工该型号高强度钢的刀具材料和切削用量。以这两种刀片在不同切削用量条件下的耐用度、加工表面粗糙度和主切削力作为刀具加工性能的评价依据,同时研究了刀片的磨、破损机理和卷、排屑稳定性。试验结果表明:涂层刀片干铣削高强度钢的加工性能优异,工件加工表面质量达到半精磨水平。     

混粉电火花加工在模具制造中的应用

通过对混粉电火花加工工艺与传统模具制造工艺的比较，从混粉电火花加工工艺的机理、表面特性、影响因素等各方面来阐述，混粉电火花加工是生产高精度、高寿命、效率的模具的最有效的工艺之一。     

Micro Textures in Concentrated-Conformal-Contact Lubrication: Effect of Distribution Patterns

Micro-scale textures may be engineered into surfaces for lubrication performance improvement. It is expected that a carefully chosen texture helps retain lubricant and enhances the hydrodynamic effect at the interface. The concept of model-based virtual texturing enables textured surfaces to be generated and “tested” through numerical simulations. This paper reports virtual texturing and simulation of a group of textured surfaces in a lubricated concentrated contact. The focus of the study is on the selection of texture distribution patterns based on their lubrication performance. Patterns of fishbone, sinusoidal, triangular, and honeycomb distributions have been investigated. The effects of texture direction, orientation angle, feature continuity, and aspect ratio are also studied. The results indicate that, for the given material and geometry system under the given conditions in the present work, the textures generating the strongest hydrodynamic lifting are short grooves with a small aspect ratio and sinusoidal waves of a small wavelength/amplitude ratio propagating in the motion direction.     

Quantitative measurement of repetitive impact damage on ground silicon nitride surfaces

Structural ceramics are finding application in automotive and truck engines. Poppet valves and valve seats, for example, require resistance to surface damage from repetitive impacts. Grinding and finishing processes can leave microcracks or residual stresses in the surfaces of ceramics which can accelerate surface-initiated degradation processes. A ball-on-inclined plane, repetitive impact testing system has been developed to study the effects of finishing method on surface durability. Tests were performed by repeatedly striking ground alumina and silicon nitride flat specimens with a silicon nitride sphere and measuring the impact damage as a function of the number of strikes. One type of alumina and three types of silicon nitride ceramics were tested. A quantitative impact damage parameter (IDP), based on mechanical stylus profiling data, was developed for use in measuring small amounts of wear. When damage did not extend beyond the depth of valleys in the machined surfaces, the IDP exhibited an excellent linear correlation with the number of impacts of silicon nitride on both silicon nitride and alumina materials. When more extensive damage occurred, a method involving digitizing the area of the contact damage from photomicrographs provided a reasonable correlation with number of impacts. These two methods are compared. Scanning electron microscopy revealed features which can affect the accuracy of impact damage measurement. Implications of the technique are discussed.     

Wear of single crystal silicon as a function of surface roughness

With increasing activities on micro electro-mechanical systems (MEMS) type microactuators, there is a growing need in understanding the tribological properties of silicon, the most commonly used wafer material for those devices. In particular, it is of interest if single crystal silicon used in microactuators exposed to rather low vertical loads is subject to wear. Therefore, wear tests using monocrystalline silicon on both sides of the tribological interface were conducted.A classic way to measure wear on sliders in contact with a tape or a rotating disk is to create an imprint using a Berkovich diamond tip mounted on a picoindenter. However, in our case we used a different approach. We created three studs on a slider’s surface by recessing the material outside the studs through an ion milling process. During the wear tests, the studs wore off. By measuring the remaining stud height, the wear volume could be determined at any point in time. The tests were performed on a pin on disk tester with a gimbaled slider to realize a flat on flat contact and a rather low normal force of 30 mN.     

电流变抛光工艺研究

研究了电流变抛光工艺参数对工件表面粗糙度的影响。用SiC和Al2O3磨料分别对硬质合金和光学玻璃进行了抛光试验，考察了抛光时间、工具电极转速、电源电压、磨料浓度等工艺参数影响工件表面粗糙度的规律。试验结果表明，随着抛光时间、工具电极转速、电源电压的增加，工件表面粗糙度逐渐降低。随着磨料浓度增加，工件表面粗糙度先降低后升高。对于表面粗糙度而言，磨料浓度存在一个最佳值。     

BT20钛合金低温铣削试验研究

为改善钛合金工件的加工表面质量,进行了低温铣削钛合金试验,并得出了合理的切削用量。     

Curve interpolation with variable feedrate for surface requirement

Finish machining of a curved surface is often carried out by an NC system with curve interpolation in the field. This function, called a NURBS interpolation, adopts a feedrate optimizing strategy based on both the geometrical information of the curved path and dynamic properties such as the curvature of the curve, the allowable acceleration and the time constant. However, in the case of a finish cut using a ball-end mill, the curve interpolator needs to take the machining process into account for improved surface roughness, while reducing the polishing time. This surface roughness on high-speed machining is theoretically defined by the feed per tooth and the pickfeed at the given radius of the tool. In this study, the effect of low machinability at the bottom of a tool on surface roughness is also considered. A curve interpolation algorithm is proposed for generating particular feedrate commands that are able to control the roughness of a curved surface. The simulation of the machined surface by the proposed algorithm was carried out, and experimental results are presented. A feedrate scheme that depends on the inclination angle has important potential application in part finishes consistent with prescribed surface roughness. The results show that the proposed algorithm is potentially useful for roughness-controlled machining of curved surface products.     

Use of the Roughness Parameters Ssk and Sku to Control Friction—A Method for Designing Surface Texturing

The aim of this work was to show that with the use of the surface roughness parameters S_sk and S_ku we can predict tribological behavior of contact surfaces and use these parameters to plan surface texturing. This article presents a continuation of our research on virtual texturing and experimental work on surface textures in the form of channels. For this investigation, steel samples were laser surface textured in the shape of dimples with different spacings between the dimples and different dimple depths. The experimental results confirmed that the parameters S_sk and S_ku can be used to design the surface texturing, where a higher value of S_ku and more negative S_sk lead to lower friction.