High speed cutting of AZ31 magnesium alloy

Using LBR-370 numerical control lathe,high speed cutting was applied to AZ31 magnesium alloy.The influence of cutting parameters on microstructure,surface roughness and machining hardening were investigated by using the methods of single factor and orthogonal experiment.The results show that the cutting parameters have an important effect on microstructure,surface roughness and machine hardening.The depth of stress layer,roughness and hardening present a declining tendency with the increase of the cutting speed and also increase with the augment of the cutting depth and feed rate.Moreover,we established a prediction model of the roughness,which has an important guidance on actual machining process of magnesium alloy.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

High Speed Cutting Inconel 718 with Coated Carbide and Ceramic Inserts

High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional thermal resistance and the ability to retain mechanical properties at elevated temperatures of service environment over 700 ℃. However, they are classified as difficult-to-cut materials due to their high shear strength, work hardening tendency, highly abrasive carbide particles in the microstructure, strong tendency to weld and form built-up edge and low thermal conductivity. They have a tendency to maintain their strength at high temperature that is generated during machining. The Inconel 718 workpiece material used in the experiment was in the hot forged and annealed condition. The commercially available inserts (all inserts were made by Kennametal Inc.) were selected for the tests, a PVD TiAlN coated carbide, a CVD/PVD TiN/TiCN/TiN coated carbide and a CVD Al 2O 3/TiC/TiCN coated carbide were used at the cutting speed range about 50～100 m/min. Three kinds Sialon grade inserts with various geometry and cutting angles were used at the cutting speed range from 100 m/min to 300 m/min. For evaluating the inserts machinability when high speed cutting Inconel 718, Taylor Formula within certain cutting speeds, an high speed cutting experiment of tool life was carried out to establish the models of tool life by means of rapid facing turning test. The conclusions drawn from the turning of Inconel 718 with silicon nitride based ceramic; PVD and CVD coated carbide inserts are as follows: Studies on tool wear in high speed machining. The thorough investigations and studies were made on the tool wear form, wear process and wear mechanism in high speed cutting of difficult-to-machine materials with ceramic tools and with coated carbides. The major wear mechanisms of nickel-based alloys are interactions of abrasive wear, adhesion wear, micro-breakout and chipping. Optimization analysis on the application of high speed machining. Based on the experimental results, the optimal cutting parameters were determined for machining of Inconel 718 at high speed. The recommendation of tool inserts for high speed cutting inconel 718 were ceramic inserts of KY2000 with negative rake angle and KY2100 with round type, the PVD coated carbide insert KC7310 was recommended for its lower price.

Wear Patterns and Mechanisms of Cutting Tools in High Speed Face Milling

High speed machining has received an important interest because it leads to an increase of productivity and a better workpiece surface quality. However, at high cutting speeds, the tool wear increases dramatically due to the high temperature at the tool-workpiece interface. Tool wear impairs the surface finish and hence the tool life is reduced. That is why an important objective of metal cutting research has been the assessment of tool wear patterns and mechanisms. In this paper, wear performances of PCBN tool, ceramic tool, coated carbide tool and fine-grained carbide tool in high speed face milling were presented when cutting cast iron, 45# tempered carbon steel and 45# hardened carbon steel. Tool wear patterns were examined through a tool-making microscope. The research results showed that tool wear types differed in various matching of materials between cutting tool and workpiece. The dominant wear patterns observed were rake face wear, flank wear, chipping, fracture and breakage. The main wear mechanisms were mechanical friction, adhesion, diffusion and chemical wear promoted by cutting forces and high cutting temperature. Hence, the important considerations of high speed cutting tool materials are high heat-resistance and wear-resistance, chemical stability as well as resistance to failure of coatings. The research results will be great benefit to the design and the selection of tool materials and control of tool wear in high-speed machining processes.

Research on the cutting performance and the wear mechanism of the cermet cutter in high speed turn-milling

When machining D60 steel by high speed turn-milling under the different cooling and lubricating conditions, the cutting performance and the wear mechanism of the cermet cutter are researched. With water soluble cooling fluid, the wear performance of the cermet cutter is bad, and does not adapt to the requirements of machining. However, when machining D60 by high speed turn-milling is under dry conditions, the wearing performance of the cermet cutter is very good and the cutting time lasts almost 3 hours. The wear mechanism of the cermet cutter under the water soluble cooling fluid is different from the dry condition. With the water soluble cooling fluid, a great deal of little chap units are formed since high frequency alternates heat stress. The crash and desquamate of these chap units is the main cause of the cutter wearing. Under dry cutting conditions, it is the main cause of cermet cutter wear in the felting phase intenerating causing rigid phase grains to fall.

HIGH SPEED MILLING OF GRAPHITE ELECTRODE WITH ENDMILL OF SMALL DIAMETER

Graphite becomes the prevailing electrode material in electrical discharging machining （EDM）currently.Orthogonal cutting experiments are carried out to study the characteristics of graphite chip formation process.High speed milling experiments are conducted to study tool wear and cutting forces.The results show that depth of cut has great influence on graphite chip formation.The removal process of graphite in high speed milling is the mutual result of cutting and grinding process. Graphite is prone to cause severe abrasion wear to coated carbide endmills due to its high abrasiveness nature.The major patterns of tool wear are flank wear,rake wear,micro-chipping and breakage. Cutting forces can be reduced by adoption of higher cutting speed,moderate feed per tooth,smaller radial and axial depths of cut,and up cutting.

Tool Failure Analysis in High Speed Milling of Titanium Alloys

In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have been observed both in the macro scale using a PG-1000 light microscope and in the micro scale using a Scanning Electron Microscope (SEM) respectively. These observations indicate that most of these tool fractures are the result of tool chipping. Further analysis of each chipping event has shown that beachmarks emanate from points on the cutting edge. This visual evidence indicates that the cutting edge is failing in fatigue due to cyclical mechanical and/or thermal stresses. Initial analyses explaining some of the outlying conditions for this phenomenon are discussed. Future analysis regarding determining the underlying causes of the fatigue phenomenon is then outlined.

Research on dynamic characteristics of high speed milling force based on discontinuous functions

This paper begins with a consideration of the influence of feed per revolution upon the depth of a cut and the impact of the machining method on the direction of tool pressure average and subsequent description of efficient cutting directions and the methods for load cell orientation. The paper goes further into the key conclusions concerning the dependences of the cutting depth at high-speed milling as in the case of discontinuous functions. It ends with recommendations offered for positioning of load cells for cut-up milling and cut-down milling.

格构技术在高铁隧道拱部防水板切割衬砌混凝土缺陷整治中的应用

[目的]许多与高铁隧道衬砌相关的缺陷随着高铁建成年限的增加逐渐凸显,防水板切割衬砌混凝土是其中较为严重的一种缺陷。为了减少结构扰动、降低对线路运行的影响,需采用新技术对高铁隧道拱部防水板切割衬砌缺陷进行整治。[方法]以我国西南地区某设计速度为200 km/h的高铁双线隧道为案例,对其发生拱部防水板切割衬砌混凝土后可采用的2个整治方案(现浇套拱、格构技术)进行了详细分析,并进行了结构的安全性、经济性对比评估。对格构技术缺陷整治方案的施工组织、工艺流程、防护措施及施工效果进行了重点论述。[结果及结论]与其他方案相比,格构技术整治方案充分利用了既有结构的承载能力,仅在局部区域修复隧道,对既有衬砌结构影响较小,对高铁线路的运营影响也较小。该方案能明显降低结构的主应力,减少结构位移,使缺陷衬砌的承载能力满足设计要求。

高速铣削-激光切割机床数控加工高精度控制技术

激光切割机铣削过程中会因工件变形导致表面出现凹凸不平或波浪状,表面局部区域高低不等,致使机床的浮动轴偏离实际运动轨迹,影响工件铣削加工的质量。为此,提出一种高速铣削-激光切割机床数控加工高精度控制技术。采用运动学理论、矩阵转换函数建立激光切割机床运动数学模型,利用PLC控制器、伺服驱动器及电机等搭建激光切割机床高速铣削加工控制模型,使用负反馈控制算法、位移误差函数控制机床铣削加工浮动轴运动,即当浮动轴执行上浮或者下浮运动时,若浮动轴运动轨迹偏离预设轨迹,调节PLC控制器参数来驱动电机控制作业,使其反向运动,直到落在预设轨迹上,实现铣削加工的高精度控制。实验结果表明,所提技术工件的铣削加工质量高,高速铣削过程中上浮点、下浮点控制误差最大值分别为6 mm、6 mm,铣削加工控制的响应时间为6.8 ms。

高速铁路预制装配式大跨度明洞衬砌地震响应的数值分析

结合某拟建高速铁路大跨度明洞穿越地层的工程地质和地貌,建立了地层与装配式明洞衬砌的三维有限元模型,并基于粘弹性人工边界,采用时程分析法研究了装配式大跨度明洞衬砌的地震响应,给出了装配式明洞衬砌受地震影响的薄弱部位。结果表明:在高烈度震区装配式明洞衬砌拱肩和拱脚部位以及管片接头处的应力和位移响应较大,是装配式明洞衬砌的薄弱部位,在结构设计时需加强此部位的配筋。此外,与EI波和汶川波相比,天津波对预制装配式明洞衬砌的影响较大。

圆形抗滑桩-拱形挡土板支挡性能与参数分析

为规避当前施工方法的不足,发展安全、高效和可靠的施工方法。依托东北地区某高速铁路路堑边坡工程,采用适于机械钻孔的圆形抗滑桩代替现行矩形抗滑桩,预制拱形挡土板,本文提出一种新型拱形板-桩墙支挡体系;并构建有限元模型,分析桩长、桩径、桩间距以及拱形挡土板矢跨比对新型拱形板-桩墙支挡体系支护性能的影响;揭示不同参数下桩顶水平位移与桩身内力的变化规律。研究结果表明:桩长与桩身弯矩和剪力大小呈正相关关系,与桩顶水平位移呈负相关关系。桩长超过14 m时,其对桩顶水平位移、桩身弯矩和剪力的影响效应明显减弱;随着桩间距增大,桩顶水平位移增大但变化幅度逐渐减小。拱形挡土板矢跨比增大时,桩顶水平位移、桩身弯矩和剪力均减小。影响拱形板-桩墙体系支挡性能的因素依次为桩间距、桩长、桩径和矢跨比。研究结果为圆形抗滑桩-拱形挡土板支挡体系在实际工程中的应用提供新思路。

铣削20CrMnTi钢已加工表面粗糙度的试验研究

采用正交试验法研究CBN直柄平底立铣刀高速铣削20CrMnTi淬硬钢时切削参数对已加工表面粗糙度的影响。通过极差分析方法研究了切削参数对表面粗糙度的影响程度,通过单因素试验法得到了切削参数对表面粗糙度的影响规律,建立了基于指数函数的切削参数与表面粗糙度的关系模型。利用预测模型得出的表面粗糙度与试验的结果进行误差分析,说明所建立的模型能比较准确地对表面粗糙度进行预测。试验结果表明:各因素的影响程度从大到小依次为铣削深度、每齿进给量和切削速度,表面粗糙度随每齿进给量和铣削深度的增大而增大,随切削速度的增大而减小。

大质量弹丸高速侵彻混凝土质量侵蚀试验研究

动能弹在高速侵彻混凝土目标时产生的质量侵蚀是引起侵彻效率降低的重要原因,该文开展了质量约为20 kg、直径为100 mm的高硬度弹丸以近1.0 km/s的速度侵彻C40混凝土的试验研究,对弹丸侵蚀参数和头部卵型段的变化进行了详细的描述,并对大质量弹丸的侵蚀机理进行了分析,通过计算得到了热熔侵蚀和切削侵蚀的占比。结果表明:在侵彻过程中,当不同质量弹丸以相同的初速撞击同等强度混凝土时,弹丸表面压力受弹丸质量影响,当高于某临界速度时,随着弹丸质量的增加而增大;弹丸侵彻混凝土时的质量侵蚀与弹丸质量有关,弹丸质量较小时侵蚀现象更明显。切削侵蚀占比随弹丸硬度提高而降低,提高弹丸材料硬度对降低大质量弹丸的质量侵蚀效果更加明显。

钛合金高速超声振动车削表面完整性及耐磨损性能试验研究

在可替代性弱且常被用于制造航空发动机关键部件的前提下,钛合金等难加工材料的高效高质切削面临挑战。针对钛合金Ti-6Al-4V加工表面完整性不佳和使役性能有待提升难题,开展了钛合金Ti-6Al-4V的高速车削试验,分析了高速超声振动切削技术对钛合金Ti-6Al-4V表面完整性和已加工表面耐磨损性能的改善效果,进而为钛合金Ti-6Al-4V的高质量加工提供理论支撑。结果表明,相比于普通切削,高速超声振动切削有效降低了钛合金Ti-6Al-4V的表面粗糙度,提高了表面强度和表面残余压应力,以及增强了耐磨损性能。

路堑特征对高铁红层泥岩基底蠕变上拱特性影响研究

轨面的平顺性是高速铁路(客运专线)正常运营的关键保障。近年来,红层泥岩地区深挖路堑基底持续上拱病害已导致轨面显著不平顺,严重影响高速铁路正常运营。本文以成(都)渝(重庆)客运专线内江北站为研究对象,统计沿线上拱监测数据,分析路堑中心开挖深度与路基基底上拱量值的对应关系,得出开挖卸荷是导致高铁基底上拱的重要原因。分析成渝客运专线上拱段路堑特征,将深挖路堑分为双侧对称型、双侧不对称型和单侧型。通过室内侧限单轴压缩蠕变试验获得砂、泥岩蠕变曲线,采用Burgers模型对曲线进行参数识别,用Flac3D模拟内江北站深挖路堑基底上拱特性,对比分析上拱位移与侧压力系数的模拟值与实测值,验证模型的可行性。在此基础上,模拟分析3种堑型基底上拱特性,得到最不利堑型。最后以最不利堑型为例,研究不同开挖宽深比、不同堑坡坡度下的基底泥岩上拱特性,得到最不利宽深比和坡角。研究结果可为高速铁路红层泥岩的路堑设计提供参考。

Inconel 718镍基高温合金高速切削仿真与刀具磨损机理研究

Inconel 718高温合金因强度高和导热系数低导致其切削加工性较差,采用陶瓷刀具高速切削Inconel 718时存在磨损快、寿命短等问题。通过仿真和试验对比分析,研究切削用量对切削力、切削温度和刀具磨损的影响规律,并获取高速切削过程中刀具前、后刀面温度场和应力场的动态分布规律,为镍基高温合金的高速切削及刀具设计制备提供指导依据。结果表明,切削速度对切削力和切削温度的影响程度小于背吃刀量和进给量;在选择切削参数时,优先选取较高的切削速度;沟槽磨损是抑制陶瓷刀具耐用度的关键因素,主要失效机理是黏结磨损。

复杂结构的铝合金锻件高速切削加工方法研究

以支臂零件为例,展示了零件的典型结构,并对零件进行了工艺性分析。根据零件的特点,从零件的毛坯形式、工艺装备的设计、加工设备的选择以及典型的加工工序等方面出发,设计了一套适宜的加工方案。基于高速切削加工技术的特点,详细描述了零件在高速切削情况下的加工与编程方法,并通过对零件的实际加工,验证了加工方案的可行性,进而总结出复杂结构的铝合金锻件数控高速切削的加工方法及合理的切削参数。

高铁荷载下路堤和路堑段地面振动特性现场测试与数值分析

对巴黎-布鲁塞尔高速铁路地面振动开展现场测试,对比分析了高铁运行引起的路堤和路堑段地面振动特性以及传播衰减规律。基于2.5维有限元法基本原理,推导并建立了高铁荷载下路堤和路堑段2.5维有限元动力计算模型,详细讨论了路堤和路堑设计参数对地面振动特性的影响。结果表明:距轨道较近处的地面振动幅值主要受列车轴重影响,而距轨道较远处则由中间车相邻转向架轮对的叠加效应主导。高铁运行引起的路堤和路堑段地面振动随与轨道距离增加而减小,中高频成分振动的衰减速率显著大于其他频段。路堤和路堑段地面振动1阶主频主要由列车荷载的基频f_1主导,随车速提高逐渐向高频方向移动。路堤和路堑对地面振动的衰减规律有重要影响,路堤段地面振动随与轨道间距的衰减过程可分为两个阶段,而路堑段地面振动衰减过程则可分为三个阶段,且振动在堑顶处有较为明显的局部放大现象。当与路堤段轨道间距≥19.0 m(路堑段≥23.0 m)后,地面振动Z振级VL_Z均小于80.0 dB。同时,高铁荷载下地面振动随路堤高度或路堑深度的增加而减小,当超过某一限值时,继续增加路堤高度或路堑深度难以有效减小地面振动。路堤段地面振动随路堤弹性模量的增大而减小。此外,在确保稳定性的前提下,较陡的路堑边坡更有利于减小高铁运行引起的地面振动。

高速铣削GH4169镍基高温合金切削温度的研究

为了研究GH4169镍基高温合金在高速铣削过程中不同切削用量对切削温度的影响,采用正交试验法对其进行切削仿真,并对铣削加工仿真结果进行分析,得到切削用量与切削温度的关系。为验证仿真结果的合理性和准确性,进行了GH4169镍基高温合金高速铣削加工试验,对比分析高速铣削试验和高速铣削加工仿真的结果,验证GH4169镍基高温合金高速铣削仿真模型的准确合理。在已确定的加工仿真模型基础上进行单因素试验,研究不同切削用量对切削温度的影响。结果表明:在切削速度、每齿进给量和背吃刀量均增大的条件下,铣削温度都逐渐上升,但增长速率呈下降趋势。