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 characte...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.展开更多
Ti Ni shape memory alloys（SMAs） have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditiona...Ti Ni shape memory alloys（SMAs） have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditional machining of SMAs is quite complex due to these properties. Hence, the wire electric discharge machining（WEDM） characteristics of Ti Ni SMA was studied. The experiments were planned as per L27 orthogonal array to minimize the experiments, each experiment was performed under different conditions of pulse duration, pulse off time, servo voltage, flushing pressure and wire speed. A multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization. The analysis of means（ANOM） and analysis of variance（ANOVA） on signal to noise（S/N） ratio were performed for determining the optimal parameter levels. Taguchi analysis reveals that a combination of 1 μs pulse duration, 3.8 μs pulse off time, 40 V servo voltage, 1.8×105 Pa flushing pressure and 8 m/min wire speed is beneficial for simultaneously maximizing the material removal rate（MRR） and minimizing the surface roughness. The optimization results of WEDM of Ti Ni SMA also indicate that pulse duration significantly affects the material removal rate and surface roughness. The discharged craters, micro cracks and recast layer were observed on the machined surface at large pulse duration.展开更多
In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined co...In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness（Ra）, X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy（TEM） techniques. Three zones from the surface to the interior（melting zone, heat affected zone and un-affected zone） were found in the machined composites, while the face of SiC particles on the surface toward the outside was ‘‘cut＇＇ to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024 Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.展开更多
Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. I...Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. It is due to the presence of discontinuously distributed hard ceramic with the MMCs and involvement of a large number of machining control variables. However, determination of optimal machining conditions helps the process engineer to make the process efficient and effec- tive. In the present investigation a novel hybrid multi-response optimization approach is proposed to derive the economic machining conditions for MMCs. This hybrid approach integrates the concepts of grey relational analysis （GRA）, principal component analysis （PCA） and Taguchi method （TM） to derive the optimal machining conditions. The machining experiments are planned to machine A17075/SiCp MMCs using wire-electrical discharge machining （WEDM） process. SiC particulate size and its weight percentage are explicitly considered here as the process variables along with the WEDM input variables. The derived optimal process responses are confirmed by the experimental validation tests and the results show satisfactory. The practical possibility of the derived optimal machining conditions is also analyzed and presented using scanning electron microscope （SEM） examinations. According to the growing industrial need of making high performance, low cost components, this investigation provides a simple and sequential approach to enhance the WEDM performance while machining MMCs.展开更多
为了提升电火花线切割(Wire cut Electric Discharge Machining,WEDM)加工后的TC4钛合金表面质量,减少表面重熔层厚度,采用不同浓度配比(1∶4、1∶6和1∶8)的HF-HNO_(3)酸蚀溶液对钛合金试件进行化学抛光处理。实验结果表明,HF-HNO_(3)...为了提升电火花线切割(Wire cut Electric Discharge Machining,WEDM)加工后的TC4钛合金表面质量,减少表面重熔层厚度,采用不同浓度配比(1∶4、1∶6和1∶8)的HF-HNO_(3)酸蚀溶液对钛合金试件进行化学抛光处理。实验结果表明,HF-HNO_(3)酸蚀溶液能使钛合金重熔层得到显著去除,表面微裂纹得到有效控制;当HF-HNO_(3)酸蚀溶液的浓度配比为1:6时,试件能获得最低的表面粗糙度和最大的表面粗糙度下降率,并且抛光前后钛合金表面元素含量发生了不同程度的变化,Ti、Al和V元素质量分数分别提高了21.5%、41.3%和13.2%,而O、C元素质量分数分别降低了82.5%和33.6%;HF-HNO_(3)酸蚀溶液可显著改善TC4钛合金试件电火花线切割加工后的表面缺陷。钛合金重熔层结构的主要成分与化学抛光后氧化膜的主要成分相似,但与氧化膜的结构不同,这对TC4钛合金试件表面质量提升具有重要意义。展开更多
基金Provincial Key Laboratory of Precision and Micro-Manufacturing Technology of Jiangsu,China(No.Z0601-052-02).
文摘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.
文摘Ti Ni shape memory alloys（SMAs） have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditional machining of SMAs is quite complex due to these properties. Hence, the wire electric discharge machining（WEDM） characteristics of Ti Ni SMA was studied. The experiments were planned as per L27 orthogonal array to minimize the experiments, each experiment was performed under different conditions of pulse duration, pulse off time, servo voltage, flushing pressure and wire speed. A multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization. The analysis of means（ANOM） and analysis of variance（ANOVA） on signal to noise（S/N） ratio were performed for determining the optimal parameter levels. Taguchi analysis reveals that a combination of 1 μs pulse duration, 3.8 μs pulse off time, 40 V servo voltage, 1.8×105 Pa flushing pressure and 8 m/min wire speed is beneficial for simultaneously maximizing the material removal rate（MRR） and minimizing the surface roughness. The optimization results of WEDM of Ti Ni SMA also indicate that pulse duration significantly affects the material removal rate and surface roughness. The discharged craters, micro cracks and recast layer were observed on the machined surface at large pulse duration.
基金supported by the National Natural Science Foundation of China(No.51501047)China Postdoctoral Science Foundation(No.2016M590280)the Fundamental Research Funds for the Central Universities(Nos.HIT.NSRIF.20161,HIT.MKSTISP.201615)
文摘In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness（Ra）, X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy（TEM） techniques. Three zones from the surface to the interior（melting zone, heat affected zone and un-affected zone） were found in the machined composites, while the face of SiC particles on the surface toward the outside was ‘‘cut＇＇ to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024 Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.
文摘Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. It is due to the presence of discontinuously distributed hard ceramic with the MMCs and involvement of a large number of machining control variables. However, determination of optimal machining conditions helps the process engineer to make the process efficient and effec- tive. In the present investigation a novel hybrid multi-response optimization approach is proposed to derive the economic machining conditions for MMCs. This hybrid approach integrates the concepts of grey relational analysis （GRA）, principal component analysis （PCA） and Taguchi method （TM） to derive the optimal machining conditions. The machining experiments are planned to machine A17075/SiCp MMCs using wire-electrical discharge machining （WEDM） process. SiC particulate size and its weight percentage are explicitly considered here as the process variables along with the WEDM input variables. The derived optimal process responses are confirmed by the experimental validation tests and the results show satisfactory. The practical possibility of the derived optimal machining conditions is also analyzed and presented using scanning electron microscope （SEM） examinations. According to the growing industrial need of making high performance, low cost components, this investigation provides a simple and sequential approach to enhance the WEDM performance while machining MMCs.
文摘为了提升电火花线切割(Wire cut Electric Discharge Machining,WEDM)加工后的TC4钛合金表面质量,减少表面重熔层厚度,采用不同浓度配比(1∶4、1∶6和1∶8)的HF-HNO_(3)酸蚀溶液对钛合金试件进行化学抛光处理。实验结果表明,HF-HNO_(3)酸蚀溶液能使钛合金重熔层得到显著去除,表面微裂纹得到有效控制;当HF-HNO_(3)酸蚀溶液的浓度配比为1:6时,试件能获得最低的表面粗糙度和最大的表面粗糙度下降率,并且抛光前后钛合金表面元素含量发生了不同程度的变化,Ti、Al和V元素质量分数分别提高了21.5%、41.3%和13.2%,而O、C元素质量分数分别降低了82.5%和33.6%;HF-HNO_(3)酸蚀溶液可显著改善TC4钛合金试件电火花线切割加工后的表面缺陷。钛合金重熔层结构的主要成分与化学抛光后氧化膜的主要成分相似,但与氧化膜的结构不同,这对TC4钛合金试件表面质量提升具有重要意义。
