A new analytical chip formation model is proposed for micro-end-milling operations. The model calculates an instantaneous uncut chip thickness by considering the combination of exact trochoidal trajectory of the tool ...A new analytical chip formation model is proposed for micro-end-milling operations. The model calculates an instantaneous uncut chip thickness by considering the combination of exact trochoidal trajectory of the tool tip and tool run-out, while the simplified circular trajectory and the neglected run-out create negligible change in conventional-scale chip formation models. Newton-Raphson iterative method is employed during the calculation to obtain quadratic convergence. The proposed approach allows the calculation of instantaneous uncut chip thickness to be done accurately and rapidly, and the prediction accuracy of this model is also verified by comparing the simulation results to experimental cutting forces.展开更多
Magnesium and magnesium in-situ composites have significant potential in the application of design and manufacturing for automotive and aerospace industries because of their high specific strength and reduced fuel con...Magnesium and magnesium in-situ composites have significant potential in the application of design and manufacturing for automotive and aerospace industries because of their high specific strength and reduced fuel consumption.But there are many challenges for machining of Mg based alloys and composites because of the high tendency of fire and oxidation.These challenges can be minimized through microstructural engineering.In this present study,the machining performances of AZ91 Mg alloy and in-situ hybrid TiC+TiB_(2)reinforced AZ91 metal matrix composite was investigated.The effectβ-Mg_(17)Al_(12)phases and grain refinement with and without in-situ particles on machinability were studied through microstructural engineering via aging and friction stir processing.The end milling operation was carried out at different cutting speeds ranging from 25 mm/min to 90 mm/min under dry environment by using an AlTiN-coated tungsten carbide tool.The optimum cutting speed for machining was found to be 75 mm/min based on the surface roughness values of all conditioned materials.The base material with dendritic microstructure was found to have poor machinability in terms of inadequate surface finish and edge-burrs formation.The combined effect of in-situ TiC+TiB_(2)particles addition and grain refinement enhanced the machining performance of the material with superior surface finish,negligible edge-burr formation and better tool wear resistance.The influence of in-situ TiC+TiB_(2)particles,β-Mg_(17)Al_(12)phases and grain refinement on machining characteristics are explained based on the tool wear mechanisms,chip behavior and machining induced affected zone.展开更多
基金supported by National Natural Science Foundation of China (No.50575134)
文摘A new analytical chip formation model is proposed for micro-end-milling operations. The model calculates an instantaneous uncut chip thickness by considering the combination of exact trochoidal trajectory of the tool tip and tool run-out, while the simplified circular trajectory and the neglected run-out create negligible change in conventional-scale chip formation models. Newton-Raphson iterative method is employed during the calculation to obtain quadratic convergence. The proposed approach allows the calculation of instantaneous uncut chip thickness to be done accurately and rapidly, and the prediction accuracy of this model is also verified by comparing the simulation results to experimental cutting forces.
基金the Ministry of Human Resource and Development for funding this Co E through Grant No.-SB20210992MEMHRD008517the support of the FIST grant,Department of Science and Technology,India(Grant#SR/FST/ET11059/2012(G))for the use of the electron microscopy facility
文摘Magnesium and magnesium in-situ composites have significant potential in the application of design and manufacturing for automotive and aerospace industries because of their high specific strength and reduced fuel consumption.But there are many challenges for machining of Mg based alloys and composites because of the high tendency of fire and oxidation.These challenges can be minimized through microstructural engineering.In this present study,the machining performances of AZ91 Mg alloy and in-situ hybrid TiC+TiB_(2)reinforced AZ91 metal matrix composite was investigated.The effectβ-Mg_(17)Al_(12)phases and grain refinement with and without in-situ particles on machinability were studied through microstructural engineering via aging and friction stir processing.The end milling operation was carried out at different cutting speeds ranging from 25 mm/min to 90 mm/min under dry environment by using an AlTiN-coated tungsten carbide tool.The optimum cutting speed for machining was found to be 75 mm/min based on the surface roughness values of all conditioned materials.The base material with dendritic microstructure was found to have poor machinability in terms of inadequate surface finish and edge-burrs formation.The combined effect of in-situ TiC+TiB_(2)particles addition and grain refinement enhanced the machining performance of the material with superior surface finish,negligible edge-burr formation and better tool wear resistance.The influence of in-situ TiC+TiB_(2)particles,β-Mg_(17)Al_(12)phases and grain refinement on machining characteristics are explained based on the tool wear mechanisms,chip behavior and machining induced affected zone.