Influence of Input Factors on Surface Roughness and Material Removal Speed when Wire-EDM a Hardened SKD11 Steel Curve Profile

The goal of this research is to identify the best set of process machining parameters for wire-EDM(Electrical Discharge Machining)cutting of hardened SKD11 steel when machining a curve profile.The multi-objective function includes reducing surface roughness and increasing MRR(Material Removal Rate).The optimization process is prepared by using Taguchi method coupled Grey Relational Analysis.The obtained results revealed that Toff has the greatest influence on the average grey value(48.30%),followed by the influence of WF(Wire Feed,15.99%),VM(Cutting Voltage,9.33%),SV(Server Voltage,5.05%),Ton(Pulse on Time,1.81%),while SPD(Cutting Speed)has a negligible effect(0.89%).Moreover,using the optimal set of machining parameters generates in surface roughness of 1.25399mm and MRR of 26.5562 mm^(2)/min.The verification experiment and Anderson-Darling method demonstrate the validity of the proposed model,which can be utilized for estimating surface roughness and MRR.

On investigating the soda-lime shot blasting of AZ31 alloy:Effects on surface roughness,material removal rate,corrosion resistance,and bioactivity

In the present study,a novel method of surface finish improvement is proposed using shot blasting of soda lime(SBSL)beads on the Mg-AZ31 alloy.The effect of the soda blasting process parameters,such as blast pressure,stand-off distance,and blast duration,have been studied in-response of material removal rate(MRR)and surface roughness(SR)and corresponding statistical models have been obtained.The multi-objective optimization has also been performed to obtain parameters for maximum MRR and minimum SR.The corrosion behavior of the treated specimens has been performed to study their in-vitro biodegradability in simulated body fluid(SBF)for 1,3,7,10,15,and 21 days.The wettability study of the SBSL treated samples has been investigated using sessile drop methodology.Further,cell adhesion test has also been performed to study the biocompatibility characteristics of the SBSL treated samples using Huh7 liver cell lines.Based on obtained quantitative data as well as scanning electron microscopy analysis of treated samples,the SBSL treatment of the AZ31 alloy has been found highly useful in producing biocompatibility surfaces along with desirable morphological features.

Modeling and analysis for material removal and surface roughness in fluid jet polishing of optical glass

luid jet polishing(FJP)is a non-contact polishing technology that can fabricate free-form optical surfaces with sub-micron-level form accuracy and nano-level surface roughness,especially for hard and brittle materials.The surface generation model of FJP can be used to guide the determination and optimization of process parameters and is of great significance for understanding the evolution mechanism of surface microtopography.However,predictive models for the microscopic topography of polished surfaces are still lacking.This study established a macroscopic surface profile model for predicting 3D material removal characteristics and surface texture by combining the 3D computer fluid dynamics(CFD)simulation model and single-particle erosion mechanism.A fractal theory-based erosion model has been built to calculate the material removal caused by the erosion of a single abrasive particle on the rough surface;thus,it predicts the micro-topography and surface roughness of the polished samples.A series of polishing experiments were conducted to analyze the feasibility and accuracy of the model quantitatively and study the influence mechanism of process parameters on the material removal characteristics and surface quality.Results indicated that the models could well predict material removal and surface roughness.The prediction accuracy of the surface roughness Ra and maximum removal depth is better than 91.6%and 90%,respectively.It is also found that the material removal rate of FJP could reach 0.517 mm3/min,and the surface roughness convergence rate could reach 62.9%.

PREDICTION OF SURFACE ROUGHNESS FOR END MILLING TITANIUM ALLOY USING MODIFIED PARTICLE SWARM OPTIMIZATION LS-SVM

It is difficult to construct the prediction model for titanium alloy through analyzing the formation mechanism of surface roughness due to the complicated relation between influential factors and surface roughness.A novel algorithm based on the modified particle swarm optimization ( PSO ) least square support vector machine ( LSSVM ) is proposed to predict the roughness of the end milling titanium alloys.According to Taguchi method and features in milling titanium alloys , the influences of cutting speed , feed rate and axial depth of cut on surface roughness are investigated with the analysis of variance ( ANOVA ) of the experimental data.The research results show that the construction speed of the modified PSO LS-SVM model is two orders of magnitude faster than that of back propagation ( BP ) model.Moreover , the prediction accuracy is about one order of magnitude higher than that of BP model.The modified PSO LS-SVM prediction model can explain the influences of cutting speed , feed rate and axial depth of cut on the surface roughness of titanium alloys.Either a higher cutting speed , a lower feed rate or a smaller axial depth of cut can lead to the decrease of surface roughness.

Thermal-Mechanical Efect and Removal Mechanism of Ti-6Al-4V During Laser-Assisted Grinding

The low density and high corrosion resistance of titanium alloy make it a material with various applications in the aerospace industry. However, because of its high specifc strength and poor thermal conductivity, there are problems such as high cutting force, poor surface integrity, and high cutting temperature during conventional machining. As an advanced processing method with high efciency and low damage, laser-assisted machining can improve the machinability of titanium alloy. In this study, a picosecond pulse laser-assisted scratching (PPLAS) method considering both the temperature-dependent material properties and ultrashort pulse laser’s characteristics is frst proposed. Then, the efects of laser power, scratching depth, and scratching speed on the distribution of stress and temperature feld are investigated by simulation. Next, PPLAS experiments are conducted to verify the correctness of the simulation and reveal the removal behavior at various combinations of laser power and scratching depths. Finally, combined with simulated and experimental results, the removal mechanism under the two machining methods is illustrated. Compared with conventional scratching (CS), the tangential grinding force is reduced by more than 60% and the material removal degree is up to 0.948 during PPLAS, while the material removal is still primarily in the form of plastic removal. Grinding debris in CS takes the form of stacked fakes with a “fsh scale” surface, whereas it takes the form of broken serrations in PPLAS. This research can provide important guidance for titanium alloy grinding with high surface quality and low surface damage.

Dissolution Characteristics of New Titanium Alloys in Electrochemical Machining

We focus on the electrochemical dissolution characteristics of new titanium alloys such as near-αtitanium alloy Ti60,α+βtitanium alloy TC4andβtitanium alloy Ti40 which are often used for aerospace industry.The experiments are carried out by electrochemical machining tool,and the surface morphology of the specimens is observed by the scanning electron microscope(SEM)and three-dimensional video microscope(DVM).The appropriate electrolyte is selected and the relationships between surface roughness and current density are achieved.The results show that the single-phase titanium alloy Ti40 has a better surface roughness after ECM compared with theα+βtitanium alloy TC4 and the near-αtitanium alloy Ti60.The best surface roughness is Ra 0.28μm when the current density is 75A/cm2.Furthermore,the surface roughness of the near-αtitanium alloy Ti60 is the most sensitive with the current density because of the different electrochemical equivalents of substitutional elements and larger grains than TC4.Finally,the suitable current density for each titanium alloy is achieved.

Effect of Electrode Materials on Electric Discharge Machining of 316 L and 17 - 4 PH Stainless Steels

Electric Discharge Machining (EDM) is one of the most efficiently employed non-traditional machining processes for cutting hard-to-cut materials, to geometrically complex shapes that are difficult to machine by conventional machines. In the present work, an experimental investigation has been carried out to study the effect of pulsed current on material removal rate, electrode wear, surface roughness and diameteral overcut in corrosion resistant stainless steels viz., 316 L and 17-4 PH. The materials used for the work were machined with different electrode materials such as copper, copper-tungsten and graphite. It is observed that the output parameters such as material removal rate, electrode wear and surface roughness of EDM increase with increase in pulsed current. The results reveal that high material removal rate have been achieved with copper electrode whereas copper-tungsten yielded lower electrode wear, smooth surface finish and good dimensional accuracy.

润滑条件对TC4钛合金切削加工影响的实验研究

为了研究冷却润滑条件及切削参数对TC4钛合金的切削力和表面粗糙度的影响,分别开展CMQL、冷风、浇注式冷却润滑条件的TC4钛合金高速切削实验、四种不同润滑环境的粗/半精/精加工实验以及CMQL条件下TC4钛合金正交切削试验,通过单因素分析和正交试验法研究冷却润滑条件及切削参数对切削加工性的影响。研究表明:CMQL冷却润滑条件可在TC4钛合金高速切削时有效降低切削阻力和改善表面粗糙度,并在高速精车削阶段体现出降低切削阻力的优势。考虑CMQL条件下高速精车TC4钛合金加工效率,最佳参数组合为较高的切削速度、较小的精加工余量和合适范围内较大的进给量。

金属钼圆基片平面研磨及其表面创成机理研究

目的实现金属钼圆基片高效平坦化加工,获得超光滑表面。方法采用游离磨料对钼圆基片进行平面研磨加工,研究磨料种类及研磨盘转速、研磨压力、研磨时间等工艺参数对研磨效果的影响规律,通过材料去除率(MRR)与表面粗糙度(Ra)的建模分析,对比钼材与高硬脆和高塑性材料,揭示其研磨工艺特性、探究其表面创成机理。结果钼圆基片材料去除快慢和表面形貌受各因素作用的综合影响。CeO_(2)磨料适合钼圆基片的研磨加工,材料去除方式为二体、三体摩擦塑性去除;在研磨过程中,MRR随研磨盘转速、研磨压力的递增而先增大后减小,在研磨盘转速为60 r/min、研磨压力为0.026 MPa条件下MRR达到最大;除磨料因素外,其他工艺因素对表面粗糙度的影响较小;MRR和Ra随加工时间的延长而趋于稳定;使用粒径W1 CeO_(2)磨料在研磨盘转速为60 r/min、研磨压力为0.026 MPa下研磨40 min后,表面粗糙度Ra由46 nm降至9.53 nm,MRR达1.16 mg/min。结论采用游离磨料研磨方法在优化工艺条件下可以有效降低表面粗糙度,获得良好表面。

TC4-DT钛合金切削加工参数研究

针对YG8和TiAlN涂层硬质合金两种刀具,通过单因素车削、低速铣削及正交高速铣削加工试验,探究刀具切削工艺参数对TC4-DT钛合金加工件表面粗糙度、表层硬度的影响规律。实验结果表明:钛合金的表面粗糙度随着切削三要素发生变化,切削速度越高,粗糙度越低;进给量越大,粗糙度越大;但随切削深度波动变化。使用TiAlN涂层硬质合金立铣刀进行加工得到的平均表面粗糙度小于YG8硬质合金立铣刀,且加工表面硬度变化更小,更适合用于TC4-DT的铣削加工。

超声辅助铣削钛合金工艺研究

由于钛合金的可加工性较差,采用传统机械加工技术难以实现高精度加工。超声加工通过对工具头施加振动来改善加工效果,将其引入钛合金加工可提高钛合金的加工性能。为提高钛合金的加工性能,分别以侧面铣削和端面铣削两种形式开展了超声辅助铣削钛合金工艺试验,探究了不同切削参数与切削形式的旋转超声加工对钛合金铣削加工的影响,并测量加工过程的切削力、加工后的工件表面粗糙度及其表面微观结构。结果表明:在侧面铣削时,超声辅助可减少加工过程中的振动、降低切削力及提高工件表面质量;在端面铣削时,超声辅助会降低加工过程的切削力,但在加工中由于超声振动作用于工件表面形成了微织构,虽然提高了工件表面形貌的均匀性,却也增大了工件的表面粗糙度值。

单晶SiC基片干式摩擦化学机械抛光初探

针对碳化硅(SiC)基片在抛光过程中效率低、费用高、环境污染大等问题,提出了一种在干式状态下对SiC基片进行摩擦化学机械抛光的方法(dry tribochemical mechanical polishing,DTCMP)。探究不同工艺参数(磨料种类、磨粒粒径、磨粒含量、抛光盘转速、抛光载荷、固相氧化剂含量)对单晶SiC基片抛光效率和表面质量的影响规律。研究结果表明:金刚石磨粒更适合SiC的摩擦化学机械抛光;当磨粒粒径为W1,磨粒质量为4 g,抛光盘转速为70r/min,抛光载荷为20.685 k Pa,固相氧化剂过碳酸钠添加量为10g时,其为最优工艺参数。采用最优工艺参数对表面粗糙度约为20nm的单晶6H-SiC基片进行干式抛光加工,最终获得表面粗糙度R_(a)为3.214 nm。DTCMP方法抛光SiC基片比水基抛光法热量损失少,所产生的界面温度更高,反应所需的活化能更低,可以实现SiC基片的绿色、高效和高质量抛光。

钛合金气门在高海拔环境中的应用优势与表面处理

在高海拔环境下,低温低压环境会导致柴油发动机的动力下降和燃烧不完全,这也会导致气门组件磨损加剧。虽然几十年来,气门制造技术已经得到了广泛探索,但是气门组件经常面临高温高压、频繁冲击和摩擦的严峻工作条件,导致摩擦磨损机制变得异常复杂,过去的气门制造优化措施并没有完全解决气门组件磨损的问题。为此,提出了一种新的解决方案,即使用铝化钛合金作为气门材料。该材料具有热强度高和重量轻的优点,非常适合用作柴油发动机气门材料。然而,由于钛铝合金的耐磨性存在短板,因此在投入实际使用之前,需要通过表面处理工艺来改善其摩擦学性能和疲劳特性。总结了多种钛铝合金表面处理方法的研究情况,包括超声表面轧制、激光表面熔覆技术、化学热处理工艺、激光表面微织构等。这些表面处理技术可以有效地改善铝化钛合金材料的摩擦学性能和疲劳特性,并消除对材料表面的负面影响。研究者们还通过使用不同的表面处理技术的复合处理来达到更好的效果。指出了未来的研究重点和方向是深入研究铝化钛合金的精确加工参数以及使用多种加工方式的可行性和作用。这将有助于更好地解决气门组件的磨损问题,提高柴油发动机的性能和可靠性。此外,还需要对铝化钛合金在其他领域的应用进行更广泛地研究和探索。

横向旋转磁场辅助电火花铣削加工烧结钕铁硼的效果研究

为了更好地解决电火花铣削加工烧结钕铁硼过程中蚀除颗粒排出困难的问题,文章引入横向旋转磁场。通过无磁场加工、横向恒定磁场辅助加工、横向旋转磁场辅助加工的加工效果对比试验,分析加工参数对材料去除率、表面粗糙度和电极损耗率的影响。从正离子的受力角度,分析无磁场、横向恒定磁场辅助、横向旋转磁场辅助电火花铣削烧结钕铁硼方法的材料去除率、电极损耗率和表面粗糙度的差异。结果表明:横向旋转磁场辅助电火花铣削烧结钕铁硼的材料去除率更高,表面粗糙度更好,电极损耗率更低。

基于响应面法的钛合金Halbach阵列增强磁流变抛光工艺参数优化

目的提高钛合金磁流变抛光的表面质量和抛光效率。方法用Halbach磁场阵列强化磁场,通过载液盘与磁铁反向旋转来增强磁流变抛光效率,使抛光头拥有更强的恢复性与自锐性。通过仿真模拟和实际测量对比研究Halbach阵列与N-S阵列的磁场分布和磁场梯度。依照试验结果描述抛光剪切力、表面粗糙度与表面微观形貌随时间的变化规律。采用响应面法优化载液盘转速、磁铁转速和加工间距等3个工艺参数,建立剪切力和表面粗糙度的拟合方程数学预测模型,并对其中的不显著项进行优化。结果在响应面交互作用分析中,工艺参数对剪切力的影响的大小顺序为加工间距、磁铁转速、载液盘转速;对表面粗糙度影响的大小顺序为载液盘转速、磁铁转速、加工间距。根据不同的需求,确定选定范围内的工艺参数组合,需要快速去除材料时,使剪切力趋于最大值的工艺参数组合为载液盘转速227 r/min,磁铁转速64 r/min,加工间距0.1 mm,通过20 min抛光后得到了表面粗糙度S_(a)为34.911 nm的光滑表面。抛光过程中,钛合金抛光所受剪切力τ为0.812 N。需要最优表面质量时,使表面粗糙度值趋于最小值的工艺参数组合为载液盘转速300 r/min,磁铁转速150 r/min,加工间距0.1 mm,通过20 min抛光后得到了表面粗糙度S_(a)为26.723 nm的光滑表面。抛光过程中,钛合金抛光所受剪切力τ为0.796 N。结论Halbach阵列拥有较高的磁场强度和富有空间变化的磁感线,能够使磁流变液中的磁链呈现出更多的姿态变化。根据响应面法优化后的剪切力和表面粗糙度预测模型,预测结果与验证试验结果相差很小,预测模型的准确度与可信度较高。

钛合金铣削加工中MQL参数优化与切削性能研究

微量润滑(MQL)铣削过程中,系统工艺参数对刀具–切屑和刀具–工件间接触界面的冷却润滑效果影响显著。本文通过有限元仿真分析了铣刀高速旋转扰动的空气流场对MQL喷射角度的影响以及切削区压力影响下的切削液渗透机理。然后,以钛合金TC4为工件材料、油膜附水滴(OoW)为润滑介质,通过正交试验研究微量润滑系统喷射角度、喷射距离和润滑油流量对铣削力的影响规律,获得油膜附水滴微量润滑(OoWMQL)系统最佳工艺参数为:喷嘴俯角30°、喷射距离10 mm、润滑油流量135 mL/h。基于此,采用OoWMQL系统最优工艺参数,开展干式铣削和水基微量润滑(WMQL)铣削下切削速度、每齿进给量对钛合金切削性能的影响研究。结果表明,相比干式铣削,WMQL方法对铣削力的改善效果较弱,而OoWMQL方法在所有参数下均明显降低了铣削力,且降低幅度最高可达50%左右。此外,采用OoWMQL方法可显著降低表面粗糙度,抑制划痕和粘屑等表面缺陷的产生,有效提高钛合金的切削加工性。

基于交变磁场辅助磁力研磨中永磁极优化试验

钛合金是新兴的结构和功能材料,TC4钛合金表面的精密加工依旧是个难题。为提高钛合金表面质量,在交变磁场磁粒研磨加工中进一步优化了永磁极的排列方式。利用有限元软件分别对未优化的交变磁场以及优化后的交变磁场进行模拟分析对比,再通过试验对比优化前后的几个交变磁场下,磁粒研磨加工TC4钛合金的表面形貌和表面粗糙度的变化情况。研究表明:在未优化交变磁场下磁粒研磨加工10 min,磁粒研磨加工工件的表面粗糙度从1.28μm降至0.38μm;在优化后磁场强度最大的交变磁场作用下,磁粒研磨加工工件的表面粗糙度从1.28μm降至0.13μm。在辅助磁粒研磨过程中,优化后的交变磁场不仅提高了加工区域内的磁感应强度,而且磁性磨粒研磨轨迹更加复杂,促进了磁性磨粒的更新,使加工后工件的表面形貌更加平整。用优化后的交变磁场辅助磁粒研磨TC4钛合金表面,提高了研磨效率,进一步提高了工件的表面质量。

不同刀具倾角下切削参数对TC4表面形貌影响规律研究

针对TC4钛合金曲面零件在精加工时因刀具倾角变化而导致表面形貌质量不稳定的问题,通过在20°,30°,40°,50°四个不同的刀具倾角下进行铣削试验,研究和分析不同刀具倾角下切削速度和每齿进给量对表面粗糙度和表面形貌的影响。结果表明:刀具倾角在20°~50°时,以v c=55m/min的切削速度加工可稳定获得较好的表面质量;除了β=30°的试件表面外,其他试件中个别切削参数组合的加工表面出现垂直于加工刀痕的振动波纹,切削速度较大或每齿进给量较大时更易产生表面振动波纹,且切削速度越大,表面振动波纹频率越高;在试验的刀具倾角范围内,表面粗糙度随着切削速度的增加有减小的趋势,各刀具倾角下的减小程度不同,但当刀具倾角较大时,由于刀具振动加剧,加工表面质量反而下降,表面粗糙度值随着切削速度的增加而增大。

基于异步旋转磁极的TC4薄板双面磁粒研磨工艺研究

目的为提升传统磁粒研磨TC4薄板的加工效率,改善表面形貌,设计了相对磁极产生相对转速差的双面磁粒研磨装置。方法基于两侧相对磁极的异步旋转,使两侧磁极产生相对转速差,进行磁性磨粒的受力和运动分析,对材料去除量进行计算分析。利用Maxwell软件,对不同的相对转速差进行磁场的模拟仿真,进而使用设计的双面磁粒研磨加工装置,对TC4薄板的双面进行研磨。最后,使用粗糙度仪和超景深3D电子显微镜,对研磨前后的工件表面进行观察分析。结果对于磁极的同步旋转,即当两侧磁极转速为500 r/min时,正面表面粗糙度Ra的平均值从0.47μm下降至0.2μm,下降幅度为57%,反面表面粗糙度Ra的平均值从0.46μm下降至0.21μm,下降幅度为54%。对于磁极异步旋转,即磁极Ⅰ转速为500r/min、磁极Ⅱ转速为600 r/min时,正面表面粗糙度Ra的平均值从0.47μm下降至0.1μm,下降幅度为78%,反面表面粗糙度Ra的平均值从0.48μm下降至0.1μm,下降幅度为79%,正面最大高度差的平均值从62.5μm下降至10.4μm,下降幅度为83%,反面最大高度差的平均值从63.2μm下降至10.3μm,下降幅度为84%,材料去除效率最高,表面质量得到有效改善。结论采用异步旋转双面磁粒研磨的方式,可以有效促进磁性磨粒的翻滚运动,加速切削刃的更新。该装置加工时能够产生相对较高的磁感应强度,磁场梯度变化适中,有利于提升表面质量,修复工件表面的缺陷,大幅度提升了研磨的效率。