This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface wi...This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.展开更多
Compaction process simulation and residual stress prediction of green PM compact were carried out with elasto-plastic 3D FEA based on the modified Drueker-Prager Cap model in Abaqus. The model parameters of the invest...Compaction process simulation and residual stress prediction of green PM compact were carried out with elasto-plastic 3D FEA based on the modified Drueker-Prager Cap model in Abaqus. The model parameters of the investigated powder Distaloy AE were determined as functions of relative density through typical mechanical property tests of powder. The model was implemented as a user subroutine USDFLD. Single sided compaction of a d20 ram^5 mm disk green compact of Distaloy AE was simulated, and the residual stress of the disk after ejection was predicted with FEA. The FEA results of the compaction process and the residual stress of the disk show good agreement with compaction experiments and X-ray diffraction measurements, which validates the model and its parameters. The results indicate that the compressive residual stresses exist mainly in a thin layer on the side surface, but the residual stresses are very small on the top and bottom surfaces.展开更多
High-velocity compaction is an advanced compaction technique to obtain high-density compacts at a compaction velocity of ≤10 m/s. It was applied to various metallic powders and was verified to achieve a density great...High-velocity compaction is an advanced compaction technique to obtain high-density compacts at a compaction velocity of ≤10 m/s. It was applied to various metallic powders and was verified to achieve a density greater than 7.5 g/cm^3 for the Fe-based powders. The ability to rapidly and accurately predict the green density of compacts is important, especially as an alternative to costly and time-consuming materials design by trial and error. In this paper, we propose a machine-learning approach based on materials informatics to predict the green density of compacts using relevant material descriptors, including chemical composition, powder properties, and compaction energy. We investigated four models using an experimental dataset for appropriate model selection and found the multilayer perceptron model worked well, providing distinguished prediction performance, with a high correlation coefficient and low error values. Applying this model, we predicted the green density of nine materials on the basis of specific processing parameters. The predicted green density agreed very well with the experimental results for each material, with an inaccuracy less than 2%. The prediction accuracy of the developed method was thus confirmed by comparison with experimental results.展开更多
The main aim of this paper is to investigate the properties of Cu-TaC electrodes produced by Powder Metallurgy （PM） method. The design of Experiment （DOE） method was used to plan the investigation. Two different c...The main aim of this paper is to investigate the properties of Cu-TaC electrodes produced by Powder Metallurgy （PM） method. The design of Experiment （DOE） method was used to plan the investigation. Two different compositions of the powders （Cu-TaC with 30 and 55 % wt TaC） were used. The major properties which determine suitability of electrodes for Electro Discharge Machining （EDM） are electrical conductivity, therrnal conductivity and to some extent density. These properties were measured for the green compacted electrodes, analyzed and compared with their sintered counterparts. This is the initial stage to determine the suitability or otherwise of the compacted electrodes. The results showed that the compacted electrodes in green form can be suitable for EDM, since the electrical conductivities are very high （94.96-189.92Ω^-1m^-1）. The thermal conductivity is good （29.70-33.20W/m K）. The density ranges between 6.13 and 9.80 g/cm3. The sintered electrodes were found to be unsuitable at the specified conditions, because they became non-conductive electrically after sintering. Current efforts are geared towards improving these properties for the sintered ones and also determining their optimum levels.展开更多
文摘This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.
基金Project(2009ZX04004-031-04) supported by the National Science and Technology Major Project of the Ministry of Science and Technology of China
文摘Compaction process simulation and residual stress prediction of green PM compact were carried out with elasto-plastic 3D FEA based on the modified Drueker-Prager Cap model in Abaqus. The model parameters of the investigated powder Distaloy AE were determined as functions of relative density through typical mechanical property tests of powder. The model was implemented as a user subroutine USDFLD. Single sided compaction of a d20 ram^5 mm disk green compact of Distaloy AE was simulated, and the residual stress of the disk after ejection was predicted with FEA. The FEA results of the compaction process and the residual stress of the disk show good agreement with compaction experiments and X-ray diffraction measurements, which validates the model and its parameters. The results indicate that the compressive residual stresses exist mainly in a thin layer on the side surface, but the residual stresses are very small on the top and bottom surfaces.
基金financially supported by the National Key Research and Development Program of China (No. 2016YFB0700503)the National High Technology Research and Development Program of China (No. 2015AA034201)+2 种基金the Beijing Science and Technology Plan (No. D161100002416001)the National Natural Science Foundation of China (No. 51172018)Kennametal Inc
文摘High-velocity compaction is an advanced compaction technique to obtain high-density compacts at a compaction velocity of ≤10 m/s. It was applied to various metallic powders and was verified to achieve a density greater than 7.5 g/cm^3 for the Fe-based powders. The ability to rapidly and accurately predict the green density of compacts is important, especially as an alternative to costly and time-consuming materials design by trial and error. In this paper, we propose a machine-learning approach based on materials informatics to predict the green density of compacts using relevant material descriptors, including chemical composition, powder properties, and compaction energy. We investigated four models using an experimental dataset for appropriate model selection and found the multilayer perceptron model worked well, providing distinguished prediction performance, with a high correlation coefficient and low error values. Applying this model, we predicted the green density of nine materials on the basis of specific processing parameters. The predicted green density agreed very well with the experimental results for each material, with an inaccuracy less than 2%. The prediction accuracy of the developed method was thus confirmed by comparison with experimental results.
文摘The main aim of this paper is to investigate the properties of Cu-TaC electrodes produced by Powder Metallurgy （PM） method. The design of Experiment （DOE） method was used to plan the investigation. Two different compositions of the powders （Cu-TaC with 30 and 55 % wt TaC） were used. The major properties which determine suitability of electrodes for Electro Discharge Machining （EDM） are electrical conductivity, therrnal conductivity and to some extent density. These properties were measured for the green compacted electrodes, analyzed and compared with their sintered counterparts. This is the initial stage to determine the suitability or otherwise of the compacted electrodes. The results showed that the compacted electrodes in green form can be suitable for EDM, since the electrical conductivities are very high （94.96-189.92Ω^-1m^-1）. The thermal conductivity is good （29.70-33.20W/m K）. The density ranges between 6.13 and 9.80 g/cm3. The sintered electrodes were found to be unsuitable at the specified conditions, because they became non-conductive electrically after sintering. Current efforts are geared towards improving these properties for the sintered ones and also determining their optimum levels.
