Microstructure Transformation and Refinement Mechanism of Undercooled Cu-Ni-Co Alloy Based on Simulation of Critical Cutting Speed in Ultrasonic Machining

Both Cu60Ni38Co2 and Cu60Ni40 alloy were naturally cooled after rapid solidification from the liquid phase.The transformation law of the microstructure characteristics of the rapidly solidified alloy with the change of undercooling(ΔT)was systematically studied.It is found that the two alloys experience the same transformation process.The refinement structures under different undercoolings were characterized by electron backscatter diffraction(EBSD).The results show that the characteristics of the refinement structure of the two alloys with low undercooling are the same,but the characteristics of the refinement structure with high undercooling are opposite.The transmission electron microscopy(TEM)results of Cu60Ni38Co2 alloy show that the dislocation network density of low undercooled microstructure is lower than that of high undercooled microstructure.By combining EBSD and TEM,it could be confirmed that the dendrite remelting fracture is the reason for the refinement of the low undercooled structure,while the high undercooled structure is refined due to recrystallization.On this basis,in the processing of copper base alloys,there will be serious work hardening phenomenon and machining hard problem of consciousness problems caused by excessive cutting force.A twodimensional orthogonal turning finite element model was established using ABAQUS software to analyze the changes in cutting speed and tool trajectory in copper based alloy ultrasonic elliptical vibration turning.The results show that in copper based alloy ultrasonic elliptical vibration turning,cutting process parameters have a significant impact on cutting force.Choosing reasonable process parameters can effectively reduce cutting force and improve machining quality.

Optimum cutting speed of block-cutting machines in natural stones for energy saving

Energy consumption of block-cutting machines represents a major cost item in the processing of travertines and other natural stones. Therefore, determining the optimum sawing conditions for a particular stone is of major importance in the natural stone-processing industry. An experimental study was carried out utilizing a fully instrumented block-cutter to investigate the sawing performances of five different types of travertine blocks during cutting with a circular diamond saw. The sawing tests were performed in the down-cutting mode. Performance measurements were determined by measuring the cutting speed and energy consumption. Then, specific energy was determined. The one main cutting parameter, cutting speed, was varied in the investigation of optimum cutting performance. Furthermore, some physico-mechanical properties of file travertine blocks were determined in the laboratory. As a result, it is found that the energy consumption （specific energy） of block cutting machines is highly affected by cutting speed. It is determined that specific energy value usually decreases when cutting speed increases. When the cutting speed is higher than the determined value, the diamond saw can become stuck in the travertine block; this situation can be a problem for the block-cutting machine. As a result, the optimum cutting speed obtained for the travertine mines examined is approximately 1.5-2.0 m/min.

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.

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.

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.

Multiscale simulation of nanometric cutting of single crystal copper——effect of different cutting speeds

A multiscale simulation has been performed to determine the effect of the cutting speed on the deformation mechanism and cutting forces in nanometric cutting of single crystal copper. The multiscale simulation model, which links the finite element method and the molecular dynamics method, captures the atomistic mechanisms during nanometric cutting from the free surface without the computational cost of full atomistic simulations. Simulation results show the material deformation mechanism of single crystal copper greatly changes when the cutting speed exceeds the material static propagation speed of plastic wave. At such a high cutting speed, the average magnitudes of tangential and normal forces increase rapidly. In addition, the variation of strain energy of work material atoms in different cutting speeds is investigated.

THE OPTIMUM CUTTING SPEED OF CIRCULAR SAW

To look for the optimum cutting speed, the tungsten carbide tipped saw was used asan example in this paper. And then, on the basis of the experimental results and theoretical calculation,the equations of tool life was introduced, and as an example, the minimum cost and maximum production cutting speed When the particleboards were cut by circulax saw, were obtained.

Effect of Cutting Speed on Surface Quality by Bandsawing

The surface profile behavior of workpieces sawn has been investigated. Six species were sawn under the condi-tion of four different kinds of cutting speed by the band saw. The real surface profile of a sawn workpiecc is composed of twosections, which arc the additivity of the waviness of filtered wave and roughness curve. The roughness of center line avernge aswell as amplitude decrease with the increasing of cutting speed for different kinds of species used in the experiment.

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.

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.

The Characteristics of Glued Tensile Shear Strength Constituted of Wood Cut by CO_(2) Laser

The performance of engineered wood products is highly associated with proper bonding and an efficient cutting method.This paper investigates the influence of CO_(2) laser cutting on the wetting properties,the modified che-mical component of the laser-cut surface,and the strength and adhesive penetration near the bondline.Beech-wood is cut by the laser with varying processing parameters,cutting speeds,gas pressures,and focal point positions.The laser-cut samples were divided into two groups,sanded and non-sanded samples.Polyvinyl acetate adhesive(PVAc)was used to bond the groups of laser-cut samples.After assembly with cold pressing,the tensile shear test was carried out.Numerical modelling was carried out to determine the partial elongation and shear strain of the glue line.Based on this,the shear modulus and linear elasticity of the glue line were estimated.Scan-ning electron microscopy was used to assess the adhesive penetration into the porosity structure of the laser-cut samples,and the depth of the heat-affected zone.The laser-cut surface was analysed by Fourier transform infrared spectroscopy.The wetting properties of the laser-cut surface were investigated by using a contact angle goni-ometer.The numerical model of the strain-stress curve confirmed the experimental model.The highest modulus of the linear elasticity of the glue in the numerical calculation belongs to the joint containing laser-cut samples at a gas pressure of 21(bar).The penetration depth of PVAc adhesive into the porosity structure of the laser-cut sam-ples was similar to that of sawn samples.The deepest heat-affected zone in the laser-cut samples was 150µm.A PVAc drop disappeared immediately on the laser-cut surface without sanding,but gradually on the sanded surface.In contrast,the drop on the sawn surface remained with an angle of 32°–48°.The degradation of hemi-cellulose and lignin was proven by the lower intensity of the C=O and C-O Bonds,compared to the sawn surface.

切削速度对某新型易切削钢切屑形态及加工表面形貌影响

为了明确切削速度对某新型易切削钢切屑形态及加工表面形貌的影响规律,开展了不同切削速度下某新型易切钢的切削试验,研究切屑形态和已加工表面形貌并分析其产生原因。结果表明:宏观上,在切削速度大于150 m/min时,该易切削钢切屑以短管螺旋状为主,当切削速度小于150 m/min时,切屑以发条状和破断弧形为主,形成锯齿形切屑的临界切削速度大约在200 m/min;切削速度影响切屑底面形貌,在低速切削时,切屑底面较多大小不一的撕裂状凹坑、沟槽,当切削速度增大至200 m/min时,能够形成表面较光滑的切屑底面;低速切削该易切削钢时,工件表面粗糙度较大,3D形貌显示波峰高度、波谷深度也均较大,随着切削速度的增加,粗糙度减小,3D形貌亦趋于平缓。

基于光速变换的激光打孔切割设备设计

传统机械加工存在加工效率低、环境友好性差等缺点,激光加工刚好解决了这些难题。激光切割打孔技术利用激光发生器输出高能量密度的激光束,激光束扫描加工表面,通过局部区域熔化气化,从而快速成型。鉴于此,设计了一款激光打孔切割设备。首先从打孔切割设备的功能与性能需求入手,分析激光打孔切割工艺内容,提出打孔机机械系统方案。根据现代化设计理论原理,借助三维建模软件,完成了X、Y、Z轴的机械结构设计。包括电机的选取、导轨和丝杠的设计算,并完成了寿命以及强度刚度的校核。通过运用PLC控制技术来实现Z轴的移动,确保激光发生器移动至需要加工的位置。根据工艺需求确定了激光发生器的选型,并分析了激光切割速度和功率对加工结果的影响。

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。

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。

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。

基于ABAQUS的微织构刀具切削钛合金仿真研究

构建无织构刀具和呈微凹坑、平行槽、垂直槽、斜向槽形貌的微织构刀具模型,并利用有限元分析软件ABAQUS研究了微织构刀具对钛合金车削过程的影响。通过分析不同形貌微织构刀具在切削过程中的切削力、摩擦系数、切削温度和工件表面残余应力,确定了较优的微织构形貌;研究了切削速度对微织构刀具切削钛合金性能的影响。结果表明,微织构刀具能有效降低切削力、摩擦系数和切削温度,使工件表面残余应力由拉应力转变为压应力,其中垂直槽微织构刀具能最有效地改善切削质量;随着切削速度的提高,切削力和切削温度增大,摩擦系数减小,工件表面残余应力由压应力向拉应力转变并有增大的趋势。

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。

车削参数对锆基合金断屑的影响

锆基合金对温度敏感,硬度不高,在粗车过程中存在温度过高、切屑易缠绕的问题。为此搭建车削平台研究锆基合金断屑机理,探究切削速度、进给量对锆基合金断屑情况、切削温度的影响。实验结果表明:提高切削速度对锆基合金断屑的影响较小,但是切削温度会随着切削速度的增加而升高;增大进给量可以显著提高断屑能力并降低切削温度。选用合适的切削参数可以有效改善锆基合金的断屑情况以及控制切削温度。

大应变切削中切削速度对纯铜纳米晶切屑微结构及性能的影响

大应变切削通过使工件材料受到刀刃的剪切和前刀面的挤压产生剧烈塑性变形从而形成高强度的超细晶切屑。采用有限元软件Deform-3D对纯铜进行大应变切削模拟,分析20°与-20°刀具前角下,切削速度对等效应变、等效应变速率和切削温度的影响规律。通过大应变切削试验,借助电子背散射衍射(EBSD)技术和维氏硬度检测等手段,对不同切削速度下纯铜切屑微观组织和力学性能进行了研究。实验结果表明:在正负前角下,随着切削速度增大,等效应变降低,等效应变速率和切削温度上升,且等效应变速率和切削温度受切削速度的影响更大;-20°刀具下得到的切屑晶粒尺寸主要分布在0.35μm以下,位错密度有明显下降趋势,硬度值由162.8HV减少至114.8HV,20°刀具下得到的晶粒尺寸主要分布在(0.2~0.6)μm之间,位错密度变化较小。硬度值由163.8HV减少至146.8HV;相比正前角,切削速度对负前角刀具制备的超细晶切屑在晶粒尺寸、位错密度和硬度方面具有更加剧烈的影响。