Study on the Predicting System of Breaking Chip When PCD Tool Cutting Aluminum Alloy

In the field of automobile manufacture, during the aluminum alloy cutting, chip forming and breaking process are very complicated. It is affected by many facto rs. Automatic machining process can not be carried through if the chip enlaces t he workpiece or the tool. So the chip control and breaking are key technology. P CD tool has many traits, such as high cutting efficiency, machining precision an d wearability. It is desired that it be used for machining coloured metals.The p aper present the study of prediction of chip breaking when PCD Tool cutting alum inum alloy with chip breaker. In the process of cutting, the method of chip brea king is up-curl-dominant chip. Therefore, based on the theory of chip breaking with chip breaker, used the cutting condition of chip breaking, this paper dedu ce the chip breaking mathematical model when cutting aluminum alloy, that is to say, the chip breaker parameters(Angle of chip break,chip groove width, bevel a ngle, the normal rake angle of chip groove, tool cutting edge angle)influence th e critical feed rate. The following conclusion can be made from theoretic analys is. The critical feed rate will decrease when the Angle of chip break and bevel angle and the normal rake angle of chip groove and tool cutting edge angle incre ase. The critical feed rate will increase when chip groove width increase. The e xperimental results are well coincided with the theoretic ones, it is proved tha t the predicting system is correct.

FORECAST OF BREAKING LENGTH OF SIDE CURLING SHORT SPIRAL CHIPS

The theoretical formula for estimating the side curling short spiral chips is simplified. On the basis of experiment, a practical formula for forecasting the chip breaking length is obtained. It is proved by experiment that the result from the practical formula fits well with that from the experiments.

Large Chip Production Mechanism under the Extreme Load Cutting Conditions

There has existed a great deal of theory researches in term of chip production and chip breaking characteristics under conventional cutting and high speed cutting conditions,however,there isn＇t sufficient research on chip formation mechanism as well as its influence on cutting state regarding large workpieces under extreme load cutting.This paper presents a model of large saw-tooth chip through applying finite element simulation method,which gives a profound analysis about the characteristics of the extreme load cutting as well as morphology and removal of the large chip.In the meantime,a calculation formula that gives a quantitative description of the saw-tooth level regarding the large chip is established on the basis of cutting experiments on high temperature and high strength steel2.25Cr-lMo-0.25V.The cutting experiments are carried out by using the scanning electron microscope and super depth of field electron microscope to measure and calculate the large chip produced under different cutting parameters,which can verify the validity of the established model.The calculating results show that the large saw-toothed chip is produced under the squeezing action between workpiece and cutting tools.In the meanwhile,the chip develops a hardened layer where contacts the cutting tool and the saw-tooth of the chip tend to form in transverse direction.This research creates the theoretical model for large chip and performs the cutting experiments under the extreme load cutting condition,as well as analyzes the production mechanism of the large chip in the macro and micro conditions.Therefore,the proposed research could provide theoretical guidance and technical support in improving productivity and cutting technology research.

Influence of longitudinal-torsional ultrasonic-assisted vibration on micro-hole drilling Ti-6Al-4V

As Ti-6 Al-4 V is a typical hard to machine material,especially in micro drilling aviation parts,chip breaking difficulty is of increasing interest to explore its further development.In this study,Longitudinal-Torsional Ultrasonic Assisted Drilling(LTUAD)was employed to machine Ti-6 Al-4 V,and its feasibility was evaluated by comparing with Conventional Drilling(CD).By combining periodical characteristics and vibration models(the separated or the unseparated ultrasonic elliptical vibration),the influence of ultrasonic frequency on the intersection characteristics of trajectories were analyzed.And the intersection characteristics were divided into four categories:even periodicity,odd periodicity,non-odd and even periodicity and composite periodicity,indicating different capability for chip breaking.By applying the longitudinal-torsional compound vibration horn,the micro-hole drilling experiment was carried out on machining center.The chip morphology,the thrust force,and the burr height were discussed.Experimental results showed that the morphology of chips presented as smaller and more fragmentary ones in LTUAD compared with continuous helical conical ones and fold-shaped ones in CD.Compared with CD,the average values of the thrust force in LTUAD reduced by 1.98%to 24.9%.According to the burr around the hole exit in both LTUAD and CD,the height of the latter was greatly affected by the drilling parameters.And the burr around the exit of the hole were distributed rather evenly with smaller extension in LTUAD.Consequently,the LTUAD employed in micro-hole drilling was effective.