FLOW STRESS MODELING FOR AERONAUTICAL ALUMINUM ALLOY 7050-T7451 IN HIGH-SPEED CUTTING

The high temperature split Hopkinson pressure bar （SHPB） compression experiment is conducted to obtain the data relationship among strain, strain rate and flow stress from room temperature to 550 C for aeronautical aluminum alloy 7050-T7451. Combined high-speed orthogonal cutting experiments with the cutting process simulations, the data relationship of high temperature, high strain rate and large strain in high-speed cutting is modified. The Johnson-Cook empirical model considering the effects of strain hardening, strain rate hardening and thermal softening is selected to describe the data relationship in high-speed cutting, and the material constants of flow stress constitutive model for aluminum alloy 7050-T7451 are determined. Finally, the constitutive model of aluminum alloy 7050-T7451 is established through experiment and simulation verification in high-speed cutting. The model is proved to be reasonable by matching the measured values of the cutting force with the estimated results from FEM simulations.

CUTTING TEMPERATURE MEASUREMENT IN HIGH-SPEED END MILLING

A computer aided measurement system is used to measure the cutting temperature directly in high-speed machining by natural thermocouples and standard thermocouples. In this system the tool/workpiece interface temperature is measured by the tool/workpiece natural thermocouple, while the temperature distribution on the workpiece surface and that of interior are measured by some standard thermocouples prearranged at proper positions. The system can be used to measure cutting temperature in the machining with the rotary cutting tools, such as vertical drill and end milling cutter. It is practically used for the research on high-speed milling with hardened steel.

CUTTING FORCES FOR HIGH-SPEED DRILLING OF COMPOSITES

The thrust and the torque of various carbide drills are studied for the high-speed drilling of fiber reinforced epoxy composites. The orthogonal experiment is carried out with different feed speeds at high rotation speed. Experimental results show that the spindle rotation speed is the most influential factor. The thrust andthe torque decrease under the condition of high rotation rate. With the decrease of the feed speed, the thrust and the torque decrease. But the effect of the feed speed is less than that of the spindle rotation rate. Moreover, the effect of drill materials on the thrust and the torque is more notable than that of the drill geometries and the feed speed. The thrust is greatly affected by the feed speed while the torque is obviously affected by drill geometries.

FORMING PRINCIPLE OF TWO SIDE-DIRECTION BURR AND IT'S PREDICTION IN METAL CUTTING

The burr is one of the common phenomena occurring i n metal cutting operations The mathematical mechanical model of two side dir ection burr formation and transformation is established with plane stress strain theory,based on the orthogonal cutting The main laws of formation and change of the burr are revealed,and it is confirmed by experiment result,which first realizes prediction of the forming and changing of the two side direction burr in metal cutting operation.

A critical review on the chemical wear and wear suppression of diamond tools in diamond cutting of ferrous metals

Diamond tools play a critical role in ultra-precision machining due to their excellent physical and mechanical material properties,such as that cutting edge can be sharpened to nanoscale accuracy.However,abrasive chemical reactions between diamond and non-diamond-machinable metal elements,including Fe,Cr,Ti,Ni,etc,can cause excessive tool wear in diamond cutting of such metals and most of their alloys.This paper reviews the latest achievements in the chemical wear and wear suppression methods for diamond tools in cutting of ferrous metals.The focus will be on the wear mechanism of diamond tools,and the typical wear reduction methods for diamond cutting of ferrous metals,including ultrasonic vibration cutting,cryogenic cutting,surface nitridation and plasma assisted cutting,etc.Relevant commercially available devices are introduced as well.Furthermore,future research trends in diamond tool wear suppression are discussed and examined.

Crosswind stability of high-speed trains in special cuts

Analysis of the aerodynamic performance of high-speed trains in special cuts would provide references for the critical overturning velocity and complement the operation safety management under strong winds.This work was conducted to investigate the flow structure around trains under different cut depths,slope angles using computational fluid dynamics(CFD).The high-speed train was considered with bogies and inter-carriage gaps.And the accuracy of the numerical method was validated by combining with the experimental data of wind tunnel tests.Then,the variations of aerodynamic forces and surface pressure distribution of the train were mainly analyzed.The results show that the surroundings of cuts along the railway line have a great effect on the crosswind stability of trains.With the slope angle and depth of the cut increasing,the coefficients of aerodynamic forces tend to reduce.An angle of 75°is chosen as the optimum one for the follow-up research.Under different depth conditions,the reasonable cut depth for high-speed trains to run safely is 3 m lower than that of the conventional cut whose slope ratio is 1:1.5.Furthermore,the windward slope angle is more important than the leeward one for the train aerodynamic performance.Due to the shield of appropriate cuts,the train body is in a minor positive pressure environment.Thus,designing a suitable cut can contribute to improving the operation safety of high-speed trains.

Finite Element Analysis and OADs Optimization of the Temperature in the Plane-strain Orthogonal Metal Cutting Process

In order to analyze the influences of the different tool’s shape and surface conditions (such as different coated and material) and their interaction on the cutting temperature, a coupled thermo-mechanical finite element analysis (FEA) model of plane-strain orthogonal metal cutting process is constructed, and 16 simulation cases with 16 different types of tools, which cover 4 rake angles, -10°, 0°, 10°, 20°, and 4 friction coefficient values, 0, 0.1, 0.2, 0.3 in the same cutting condition (cutting depth and cutting speed) have been performed. Finally the simulation results are analyzed according to the variance analysis method (VAM) of orthogonal array designs (OADs), the relationships between the rake angle, tool-workpiece interface’s friction coefficient and their interact effect to the maximum temperature value and the temperature field of the chip are obtained. This result has some instructive meaning to analyze the causes of the cutting temperature and to control the maximum temperature value and the overall temperature field in the metal cutting process.

AN EXPERIMENTAL STUDY OF CO_2 LASER CUTTING OF METALLIC COATED SHEET STEELS

An experimental investigation is outlined for the CO 2 laser cutting process of metallic coated sheet steels, GALVABOND. It shows that by proper control of the cutting parameters, good quality cuts are possible at high cutting rate. Visual examination indicates that when increasing the cutting rate to as high as 5000 mm/min (about 100 times that suggested previously), kerfs of better quality can be achieved. Some kerf characteristics such as the width, heat affected zone and dross in terms of the process parameters are also discussed. A statistical analysis has arrived at a recommendatio on the optimum cutting parameters forprocessing GALVABOND.

Improvement of Drill Performance in Metal Cutting Using MoST Solid Lubricant Coatings

Coated tools are widely used in today’s metal cutting industries and have significantly improved machining productivity through reducing operation costs and time. This paper presents the results of a systematic study of the performance of HSS drills coated with CrTiAIN and drills with a top solid lubricant coating of MoST?. The tests were performed on a Haas vertical machining centre under wet and dry cutting conditions to machine through holes in medium carbon steel workpieces. The feed force and torque were recorded throughout some of the tests using a force dynamometer, while the tool wear was monitored and measured. It was found that MoST? coatings even under accelerated conditions improve the tool life significantly based on their unique properties and very low friction.

Automation of choice of instrumental equipment and study of thermo-stressed conditions of metal-cutting instrument

This article about possibility of automations of choice of instrumental equipment. In it described problems of choice of equipment, which are decided by means of mathematical model, developed on the base of finite element method.

An Experimental Study of Cutting Performance of Ti(C, N) Based Cermet Cutting Tool

Through systematic cutting experiments, characteristics of the cutting performance of Ti(C, N) based cermets is identified. The experiments were designed to study their resistance,toughness, cutting force, tool-chip friction coefficient and machining quality by comparing them with those of WC based cemented carbides. The cutting data and the regressed empirical formulae would be useful to promote proper application of cermet cutting tool materials.

CUTTING-DIRECTION BURR FORMATION IN ORTHOGONAL PRECISION CUTTING

The cutting burr is one of the common phenomena occurring in metal cutting.In this paper,the forming processes,main effect factors and change law of the cutting direction burr in orthogonal cutting have been studied and related theories are analyzed based on the cutting experiments.The result shows that:(1)the forming processes of cutting direction burr consist of normal cutting,flexure deformation of end surface of workpiece,plastic effect,continuous cutting and shear break separating in orthogonal cutting;(2)a new phenomenon is found that cutting direction burr is formed with the shear break separation of the chip and workpiece machined surfaces;(3)the size of cutting direction burr varies with workpiece materials,cutting parameters and geometric parameters of the cutting tool.

Optimization of Abrasive Water Jet Cutting of Ductile Materials

Full factorial design of experiments was developed in order to investigate the effects of jet pressure, abrasive mixing rate, cutting feed, and plate thickness upon three response variables, surface finish of cutting wear zone, percentage proportion of striation free area, and maximum width of cut. The set of sixteen experiments was performed on each of the following two ductile materials： AISI 4340 （high strength low alloy steel, hardened to 49HRc） and Aluminum 2219. Analysis of Variance （ANOVA） was performed on experimental data in order to determine the significance of effects of different parameters on the performance measures. It was found that cutting feed and thickness were highly influential parameters, while abrasive mixing rate is influential upon surface roughness only. Strong interaction was found between jet pressure and workpiece material. Multi-criteria numerical optimization was performed in order to simultaneously maximize/minimize different combinations of performance measures.

A MECHANICS MODEL FOR CIRCULAR FORM TOOL CUTTING

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A MECHANICAL MODEL FOR THE CHIP SIDE DEFORMATION IN ALUMINIUM ALLOY CUTTING

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Prospects of Robot Laser Cutting in the Era of Industry 4.0

Laser cutting is a non-contact thermal cutting process and an integral part of manufacturing. In metal processing, laser cutting is at the forefront of the manufacturing chain followed by joining and manufacturing processes like welding. The future of metal manufacturing processes like laser cutting shall rely on intelligent systems such as automation and robotics based on the advancement of technology and digital transformation spearheaded by Industry 4.0. Moreover, the digital transition where robots and automated systems are key drivers creates a broader platform to utilize energy-efficiency materials. Such energy-efficient materials include high-strength steels (HSS) for structural applications (e.g. bio-energy structures, wind turbines, ice-going vessels) onshore, offshore and in the Arctic region. The aim of this paper is to elucidate the prospects of robot laser cutting systems in the framework of integrated metal manufacturing in future factories. Previous studies on laser cutting technologies are examined based on scientific and industrial perspectives. Robot laser cutting system is compared with the well-known flat-bed laser cutting CNC machine in several aspects including flexibility in manufacturing, ease for digitalization, off-line capabilities and investment analysis. The findings shall help to determine the competitiveness of robot laser cutting systems with flat-bed laser cutting CNC machines, especially when considering metal manufacturing in small and medium-sized enterprises (SMEs). The outcome of this study is to stir up experimental and computational research on robot laser cutting systems of metals, and help companies in their decision-making process when deciding which laser cutting system will best suit their manufacturing operations in the future.

Modeling of Transient Thermal Conditions in Cutting

The thermal conditions like the temperature distribution and the heat fluxes during metal cutting have a major influence on the machinability, the tool lifetime, the metallurgical structure and thus the functionality of the work piece. This in particular applies for manufacturing processes like milling, drilling and turning for high-value turbomachinery components like impellers, combustion engines and compressors of the aerospace and automotive industry as well as energy generation, which play a major role in modern societies. However, numerous analytical and experimental efforts have been conducted in order to understand the thermal conditions in metal cutting, yet many questions still prevail. Most models are based on a stationary point of view and do not include time dependent effects like in intensity and distribution varying heat sources, varying engagement conditions and progressive tool wear. In order to cover such transient physics an analytical approach based on Green＇s functions for the solution of the partial differential equations of unsteady heat conduction in solids is used to model entire transient temperature fields. The validation of the model is carried out in orthogonal cutting experiments not only punctually but also for entire temperature fields. For these experiments an integrated measurement of prevailing cutting force and temperature fields in the tool and the chip by means of high-speed thermography were applied. The thermal images were analyzed with regard to thermodynamic energy balancing in order to derive the heat partition between tool, chips and workpiece. The thus calculated heat flow into the tool was subsequently used in order to analytically model the transient volumetric temperature fields in the tool. The described methodology enables the modeling of the transient thermal state in the cutting zone and particular in the tool, which is directly linked to phenomena like tool wear and workpiece surface modifications.

Effects of tool flank wear on orthogonal cutting process of aluminum alloy

The tool flank begins to wear out as soon as cutting process proceeds. Cutting parameters such as cutting forces and cutting temperature will vary with increasing degree of flank wear. In order to reveal the relationship between them, the theoretical situations of cutting process were analyzed considering the tool flank wear effect. The variation rules of cutting force, residual stress and temperature distributions along with the tool flank wear were analyzed comparing with the sharp tool tip. Through FEM simulation method, affections of the tool flank wear value VB on cutting forces, residual stress and temperature distributions were analyzed. A special result in this simulation is that the thrust force is more sensitive to tool flank wear, which can be used as a recognition method of tool condition monitoring. The FEM simulation analysis result agrees well with the experimental measuring data in public literatures and some experiments made also by the authors.

Elliptical vibration chiseling:a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface

High-aspect-ratio metallic surface microstructures are increasingly demanded in breakthrough applications,such as high-performance heat transfer enhancement and surface plasmon devices.However,the fast and cost-effective fabrication of high-aspect-ratio microstructures on metallic surfaces remains challenging for existing techniques.This study proposes a novel cutting-based process,namely elliptical vibration chiseling(EV-chiseling),for the high-efficiency texturing of surface microstructures with an ultrahigh aspect ratio.Unlike conventional cutting,EV-chiseling superimposes a microscale EV on a backward-moving tool.The tool chisels into the material in each vibration cycle to generate an upright chip with a high aspect ratio through material deformation.Thanks to the tool’s backward movement,the chip is left on the material surface to form a microstructure rather than falling off.Since one microstructure is generated in one vibration cycle,the process can be highly efficient using ultrafast(>1 kHz)tool vibration.A finite element analysis model is established to explore the process mechanics of EV-chiseling.Next,a mechanistic model of the microstructured surface generation is developed to describe the microstructures’aspect ratio dependency on the process parameters.Then,surface texturing tests are performed on copper to verify the efficacy of EV-chiseling.Uniformed micro ribs with a spacing of 1–10μm and an aspect ratio of 2–5 have been successfully textured on copper.Compared with the conventional EV-cutting that uses a forward-moving tool,EV-chiseling can improve the aspect ratio of textured microstructure by up to 40 times.The experimental results also verify the accuracy of the developed surface generation model of microstructures.Finally,the effects of elliptical trajectory,depth of cut,tool shape,and tool edge radius on the surface generation of micro ribs have been discussed.