Influence of Machining Parameter on Tool Life While Machining Hybrid Metal Matrix Composites

A metal matrix composite constitutes a continuous metallic matrix and a discontinuous phase known as reinforcement. The hybrid metal matrix composites (Hmmcs) have been used to manufacture drive shafts, disc brake rotors, brake drums, connecting rods pistons, engine block cylinder liners for automotive and rail vehicle applications. The Hmmcs castings of diameter 120 mm and length 300 mm were prepared through sand mould technique following stir casting methodology. The cast components further subjected to evaluation of physical properties and machining tests using two grades of coated inserts and PCD inserts. The experiments were carried out following ISO 3685 standards. The coating thickness of the TiN coated and TiAlN coated inserts were measured using Kalo testing method; the results of the test show that the interface of the substrate and coating was free from the porosity, and the coating thickness of TiN coating was 4.84 microns and TiAlN coating was measured 4.6 microns. The results of the experiments show that performance of the PCD insert was better than coated inserts at 0.1 mm/rev feed; however at 0.2 mm/revolution feed PCD insert failed by micro chipping of cutting edge while machining Hmmcs. When TiAlN coated inserts were used to machine Hmmcs the coated inserts failed by gradual wear and BUE formation.

Tool life modeling for evaluating the effects of cutting speed and reinforcements on the machining of particle reinforced metal matrix composites

The wear of cutting tools in the machining of 2024Al alloy composites reinforced with Al2O3 particles using varying sizes and volume fractions of particles up to 23.3vol% was investigated by a turning process using coated carbide tools K10 and TP30 at different cut- ting speeds. Machining tests were performed with a plan of experiments based on the Taguchi method. The tool life model was developed in terms of cutting speed, size, and volume fraction of particles by multiple linear regressions. The analysis of variance （ANOVA） was also employed to carry out the effects of these parameters on the cutting tool life. The test results show that the tool life decreases with the increase of cutting speed for both cutting tools K10 and TP30, and the tool life of the K10 tool is significantly longer than that of the TP30 tool. For the tool life, cutting speed is found to be the most effective factor followed by particle content and particle size, respectively. The predicted tool life of cutting tools is found to be in very good agreement with the experimentally observed ones.

Research on the Seebeck effect in efficient turning process and improving tool life

In this paper, for the tool wear problem of the cutting process, the study on improving tool life has been done through the analysis of the Seebeck effect in the efficient turning process. The generation principle of the self-excited electric current in the cutting process is studied, and also its effect on the life of the turning cutter is studied, so as to reveal the mechanism of the self-excited electric current accelerating the wear of cutting tools. The study results show that the self-excited electric current which is generated during the cutting process is one of the main reasons that cause both the accelerated hardening and the low life of cutting tools to happen. Thus, if the generation of self-excited current is avoided and reduced, the cutting performance of cutting tools can be effectively improved, so to improve the tool life. The study can provide the anti-friction and anti-wear theory basis for the design of the efficient cutting tools.

Influence of Machining Parameter on Surface Roughness and Tool Life While Machining EN24 Grade Alloy Steel

The requirements of high quality machined surface as well as demand of enhanced contact time of cutting tools drive towards adopting multilayer coated carbide inserts. The industry requires higher productivity, hence higher machining parameters need to be used in order to meet the industry requirements. The alloy steel material used to fabricate machine parts consists of alloying elements like nickel, chromium and molybdenum difficult to machine, since the cutting tool fails by high tool wear, if we use uncoated carbide inserts to machine alloy steels. Hence in the present research work it is intended to use tungsten carbide inserts coated with different coatings for the experiments. The turning experiments were carried out using different grades of uncoated and coated carbide inserts of identical tool signature. The cutting speed selected for the experiments was 100 to 500 m/min in steps of 100 m/min, and the feed per revolution was 0.1 mm to 0.4 mm in step of 0.1 mm. The experimentation was carried out following ISO3685 standards. The results of the experiments revealed that the surface roughness measured was the least at cutting speed 500 m/min and feed per revolution of 0.1 mm, however the chip breaking found better when the feed used was greater than 0.2 mm/revolution.

Investigation on tool wear and tool life prediction in micro-milling of Ti-6Al-4V

Short tool life and rapid tool wear in micromachining of hard-to-machine materials remain a barrier to the process being economically viable. In this study, standard procedures and conditions set by the ISO for tool life testing in milling were used to analyze the wear of tungsten carbide micro-end-milling tools through slot milling conducted on titanium alloy Ti-6 Al-4 V. Tool wear was characterized by flank wear rate,cutting-edge radius change, and tool volumetric change. The effect of machining parameters, such as cutting speed and feedrate, on tool wear was investigated with reference to surface roughness and geometric accuracy of the finished workpiece. Experimental data indicate different modes of tool wear throughout machining, where nonuniform flank wear and abrasive wear are the dominant wear modes. High cutting speed and low feedrate can reduce the tool wear rate and improve the tool life during micromachining.However, the low feedrate enhances the plowing effect on the cutting zone, resulting in reduced surface quality and leading to burr formation and premature tool failure. This study concludes with a proposal of tool rejection criteria for micro-milling of Ti-6 Al-4 V.

WEAR AND LIFE OF PCBN TOOLS WHEN DRY-CUTTING BEARING STEEL GCr15

The wear forms and reasons of PCBN tools when dry-cutting bearing steel GCr15are studied systematically. The effect law of the workpiece hardness on PCBN tools is gained andtool wearing with the quickest speed at the workpiece critical hardness is proved. The life equationat two kinds of workpiece hardness demonstrates that the effect of the cutting speed on the PCBNtool life is less than that of carbide tools and ceramic tools.

Multi-verse optimizer based parameters decision with considering tool life in dry hobbing process

Dry hobbing has received extensive attention for its environmentally friendly processing pattern.Due to the absence of lubricants,hobbing process is highly dependent on process parameters combination since using unreasonable parameters tends to affect the machining performance.Besides,the consideration of tool life is frequently ignored in gear hobbing.Thus,to settle the above issues,a multiobjective parameters decision approach considering tool life is developed.Firstly,detailed quantitative analysis between process parameters and hobbing performance,i.e.,machining time,production cost and tool life is introduced.Secondly,a multi-objective parameters decision-making model is constructed in search for optimum cutting parameters(cutting velocity v,axial feed rate f_(a))and hob parameters(hob diameter d_(0),threads z_(0)).Thirdly,a novel algorithm named multi-objective multi-verse optimizer(MOMVO)is utilized to solve the presented model.A case study is exhibited to show the feasibility and reliability of the proposed approach.The results reveal that(i)a balance can be achieved among machining time,production cost and tool life via appropriate process parameters determination;(ii)optimizing cutting parameters and hob parameters simultaneously contributes to optimal objectives;(iii)considering tool life provides usage precautions support and process parameters guidance for practical machining.

Comparative study on machinability improvement in hard turning using coated and uncoated carbide inserts： part II modeling, multi-response optimization, tool life, and economic aspects

The present study focused on mathematical modeling, multi response optimization, tool life, and eco- nomical analysis in finish hard turning of AISI D2 steel （（55 4- 1） HRC） using CVD-coated carbide （TiN/TiCN/ A1203） and uncoated carbide inserts under dry environ- mental conditions. Regression methodology and the grey relational approach were implemented for modeling and multi-response optimization, respectively. Comparative economic statistics were carried out for both inserts, and the adequacy of the correlation model was verified. The experimental and predicted values for all responses were very close to each other, implying the significance of the model and indicating that the correlation coefficients were close to unity. The optimal parametric combinations for A1203 coated carbide were dl-fl-v2 （depth of cut = 0.1 mm, feed = 0.04 mm/r and cutting speed = 108 m/min）, and those for the uncoated tool were dl-（0.1 mm）-fl （0.04 mm/r）-vl （63 rn/min）. The observed tool life for the coated carbide insert was 15 times higher than that for the uncoated carbide insert, considering flank wear criteria of 0.3 mm. The chip volume after machining for the coated carbide insert was 26.14 times higher than that of the uncoated carbide insert and could be better utilized for higher material removal rate. Abrasion, diffusion, notch- ing, chipping, and built-up edge have been observed to be the principal wear mechanisms for tool life estimation. Use of the coated carbide tool reduced machining costs by about 3.55 times compared to the use of the uncoated carbide insert, and provided economic benefits in hard turning.

MODELING AND OPTIMIZATION OF THE CUTTING FLUID FLOW AND PARAMETERS FOR INCREASING TOOL LIFE IN SLOT MILLING ON St52

In this paper the CNC machining of St52 was modeled using an artificial neural network(ANN)in the form of a four-layer multi-layer perceptron(MLP).The cutting parameters used in the model were cutting fluid flow,feed rate,spindle speed and the depth of cut and the model output was the tool life.For obtaining more accuracy and spending less time Taguchi design of experiment(DOE)has been used and correlation between the output of the ANN and the experimental results was 96%.Further optimization process has been done by use of a genetic algorithm(GA).After optimization process tool life was increased about 8%equal to 33 min and was corroborated by experimental tests.This demonstrates that the coupling of an ANN with the GA optimization technique is a valid and useful approach to use.

Influences of Tool Wear on Residual Stress and Fatigue Life of Workpiece in Hard Cutting Process

Tool wear has an important influence on the residual stress distribution on the machined surface.Also,it will influence the fatigue life of finished workpiece. In this research,the hard turning process of hardened die steel Cr12 MoV was studied by using PCBN tool with considering tool wear. Based on the numerical treatment of residual stress,the dispersion and distribution curves of different tool wear were fitted,and the influence mechanism of tool wear on the residual stress distribution of machined surface was analyzed.Based on the theory of fatigue mechanics and mathematical statistics,the mathematical model for difference of stress dispersion and fatigue life was established. The rotating and bending tests were carried out on the standard parts after cutting process for the workpiece. The influence of tool wear on fatigue life was revealed by fracture surface morphology and fatigue life study. The results provide theoretical support for control of residual stress and the fatigue property of the machined surface under the actual working conditions.

Machinability of Hastelloy C-276 Using Hot-pressed Sintered Ti(C_7N_3)-based Cermet Cutting Tools

C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti（C7N3）-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 m/min, depth of cut of 0.4 mm and feed rate of 0.15 mm/r if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm^3/min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 m/min, depth of cut of 0.6 mm and feed rate of 0.1 mm/r. In this case, the surface roughness is 0.59μm. Notch wear, flank wear, chipping at the tool nose, built-up edge（BUE） and micro-cracks are found when Ti（C7N3）-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.

Application of Response Surfaces in Evaluating Tool Performance in Metalcutting

This paper advances the collection of statistical methods known as response surface methods as an effective experimental approach for describing and comparing the tool life performance capabilities of metalcutting tools. Example applications presented demonstrate the versatility of the power family of transformations considered by Box and Cox (1964) in modeling tool life behavior as revealed using simple response surface designs. A comparative analysis illustrates a method to gauge the statistical significance of differences in tool life estimates computed from response surface models. Routine use of these methods in experimental tool testing is supported by their ability to produce reliable relative performance representations of competing tools in field applications.

铣削高温合金GH3039刀具寿命预测及磨损机理

为揭示高温合金GH3039铣削参数对刀具寿命的影响规律,采用正交试验法对其进行铣削试验,运用多元回归法建立刀具寿命预测模型,分析铣削参数对刀具寿命的影响规律,通过观测铣刀后刀面的磨损情况,探究不同主轴转速下铣刀的磨损机理。结果表明:主轴转速对刀具寿命的影响程度最大,最小为轴向切深;当主轴转速为750 r/min时,铣刀磨损区域主要以黏结磨损和磨粒磨损为主;当铣削速度为950 r/min时,氧化磨损与扩散磨损开始增强;当铣削速度为1 180 r/min时,磨粒磨损与黏结磨损开始减弱甚至消失,氧化磨损与扩散磨损占据主导地位。

基于刀具寿命的新型螺旋槽丝锥设计

以螺旋槽丝锥参数分析为依据,对M24螺旋槽丝锥的材料选用、表面状态、热处理方法和工艺、刀具结构参数、切削液的选择和刀具寿命进行了研究和优化设计。分析了M24螺旋槽丝锥的热处理工艺参数和金相组织。通过寿命分析发现,研制的丝锥切削扭矩、排屑能力、切屑情况及刀具耐用度与进口丝锥基本相当。本文研究具有一定的应用价值。

Head and Neck Cancer Early Identification of Malnutrition High Risk Patients and Quality of Life Optimization

Malnutrition in Head and neck cancer (HNC) patients can be present at the moment of diagnosis. The nutritional status is determinant for the treatment success and quality of life of the patients. The nutritional status gradually declines during treatment and the majority of patients undergoing treatment will need nutritional therapy. On the other hand, HNC, like other cancers, can induce a paraneoplastic syndrome that leads to cachexia. This cachexia status is most of the times the cause of death or the cause of treatment failure. So, early identification of malnutrition high risk patients is crucial to start an adequate nutrition support intervention in HNC patients. This study aims to identify HNC patients who present malnutrition or higher risk of malnutrition;to signalize variables that support early identification of high-risk patients of becoming malnourished and to establish a dynamic relationship between malnutrition risk in these patients and Quality of Life (QoL) impacts. For six months consecutive outpatients with HNC admitted at the Head & Neck Unity of Oncology Portuguese Institute—Porto were asked to participate in the research (n = 114). The European Organisation for Research and Treatment of Cancer (EORTC) cancer-specific HRQoL questionnaire-QLQ-C30 and Malnutrition Universal Screening Tool, MUST were used. At the moment of first presentation, 32 patients (28.1%) presented high-risk of malnutrition. HNC patients with oral cavity and oropharynx tumour locations, older, with low literacy or with BMI under 18.5 at the moment of diagnosis, represent a high-risk group. When HNC is considered, a dynamic and bi-directional connection between malnutrition and QoL is observed. A significant (p Emotional and social functional scales and all symptom scales—including pain, presented significant differences between high and medium risk of malnutrition patients. Fatigue, pain, insomnia, appetite loss and financial difficulties were domains directly related to high risk of malnutrition patients. Pain scores were significantly higher (43.23) in the high-risk patients when compared to medium risk patients (11.67). Nutrition support should be considered at any stage of the pathway —especially in high risk group—in order to optimize tumour treatment results, reduction of adverse effects of therapy and improving both QoL and survival.

我国绿色建筑政策研究:基于扩展钻石模型和政策工具

构建绿色建筑扩展钻石模型,明确了绿色建筑行业发展的关键要素与政府的核心效能。基于此,进一步构建绿色建筑“政策工具—全生命周期”二维分析框架,利用Nvivo12软件对62份政策文本进行编码统计与分析。研究发现,现有政策工具针对需求条件、生产要素、企业战略与支持性产业的影响有限。并提出政策建议未来的着力方向:拓展运营维护阶段政策的使用,加大需求端的激励措施;提升生产要素供应能力与质量,重视人才培养和企业能力建设;健全全流程精准管控体系,增强企业金融激励;落实技术创新扶持,完善全产业链政策体系。

基于未知函数泰勒展开的GH4169插铣刀具寿命预测

科学实验和生产实践中经常研究变量间的关系,获得相关变量的不规则的散点数据,多数情况下,这些变量之间的函数关系是未知的。本文通过泰勒展开给出了通用的函数公式,并尝试通过拟合获得相关系数(通常只选取部分最有效的加和项系数作拟合),使公式能很好地适应数据。获得能适应数据的合适的泰勒展开式,即是获得了变量之间的函数关系,将给研究和使用带来极大方便。本文研究了GH4169插铣刀具寿命的泰勒展开模型,验证了泰勒展开式预测结果优于插值和RBF网络预测结果。GH4169插铣刀具寿命的泰勒展开模型是三元函数,为便于研究,固定两个参数,只研究一个参数变化对刀具寿命的影响,所获得的规律与文献的研究结果相符。

地中海贫血病人健康相关生活质量评估工具的研究进展

对地中海贫血病人健康相关生活质量(HRQoL)常用评估工具进行综述,概述评估工具的发展、主要内容及应用现状,分析评估工具的特点与不足,旨在为临床选择合适的评估工具提供借鉴,为我国地中海贫血病人HRQoL评估工具的研制以及个体化护理提供参考。

不孕(育)症夫妻二元应对异质性研究及相关因素分析

目的·采用潜在剖面分析法探索辅助生殖技术(assisted reproductive technology,ART)治疗前不孕(育)症夫妻二元应对水平的潜在剖面,并探讨不同剖面间的差异及相关因素。方法·招募2023年9月至11月在上海交通大学医学院附属仁济医院生殖医学中心接受ART治疗的不孕(育)症初诊夫妇,应用一般资料问卷、生育压力量表(Fertility Problem Inventory,FPI)、二元应对评估工具(Dyadic Coping Inventory,DCI)、生育生活质量量表(Fertility Quality of Life Tool,FertiQoL量表)进行评估。采用潜在剖面分析探索不孕(育)症夫妻治疗前二元应对的剖面类型,比较不同剖面之间的一般特征,及FPI和FertiQoL量表得分;采用多元Logistic回归分析不同二元应对剖面的相关因素。结果·共纳入257对不孕(育)症夫妻,女性平均年龄(30.15±3.07)岁,男性平均年龄(31.82±3.82)岁,平均婚龄(3.75±2.16)年,平均不孕(2.90±1.92)年;男方导致不孕118对、女方导致不孕109对、男女共患不孕(育)症30对;男性DCI平均得分(128.25±19.15)分,女性(129.91±18.32)分。根据二元应对水平,257对夫妻可分为4个潜在剖面:共同积极组(153对,59.5%)、共同消极组(85对,33.1%)、男方积极组(12对,4.7%)及男方消极组(7对,2.7%);不同剖面不孕(育)症夫妻的年龄、FPI得分、FertiQoL量表得分、再婚比例间差异均具有统计学意义(均P<0.05)。多元Logistic回归分析结果显示,以共同积极组为参照,共同消极组的男方年龄更大(OR=1.122,95%CI 1.004~1.254,P=0.036)、男女双方FPI得分更高(男:OR=1.019,95%CI 1.003~1.035,P=0.018;女:OR=1.020,95%CI 1.004~1.036,P=0.015)、男方FertiQoL量表得分更低(OR=0.966,95%CI 0.937~0.996,P=0.029)。结论·接受ART治疗前不孕(育)症夫妻的二元应对水平可分为4个剖面类型;与共同积极应对夫妻相比,男性生育压力大、年龄大、感知的生育生活质量低,以及女性生育压力大均是夫妻共同消极应对的危险因素。

MILLER WEAR IN MILLING Ti ALLOY WITH NITROGEN GAS MEDIA

Milling Ti alloy is a very difficult technology. The primary problem is that the miller wear is very rapid and makes the miller break or rapture. Although cutting fluid is mainly used to reduce friction and temperature in cutting area to enhance tool life, it is the largest source of environmental pollution. To develop a technology for the clean and efficient milling Ti alloys, nitrogen gas is used as a cutting media in this paper. Based on lots of experiments and researches, the tool life and wear mechanism of high speed steel miller is analyzed. A conclusion is drawn that, milling with nitrogen gas media yields much longer tool life than dry milling. Tool life equations (Taylor′s equations) are derived for both milling types.