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Development of cBN electroplated end-mill combined cutting and grinding for precision machining of CFRP CFRP精密加工用cBN电镀立铣刀的研制
Q3 Engineering Pub Date : 2018-08-22 DOI: 10.1504/IJAT.2018.10015271
T. Furuki, Y. Kabaya, T. Hirogaki, E. Aoyama, Kiyofumi Inaba, K. Fujiwara
Carbon-fibre reinforced plastic (CFRP) has been applied to various fields because of its excellent mechanical properties. Generally, after fabrication with moulding, CFRP requires additional machining, such as cutting or grinding. As the cutting tool for CFRP, a diamond-coated end-mill with high wear resistance has been developed. However, burr or uncut fibre is easily formed. Meanwhile, in the case when a grinding wheel is used, the machining efficiency is low even though there are sharp edges with burr or uncut fibres. Therefore, there is a need for the development of a versatile tool that can achieve precision machining of CFRP with high efficiency. This study develops a cBN electroplated end-mill that is a combination of a cutting tool and a grinding wheel. This report shows that the developed tool is able to perform high-efficiency cutting like the diamond coated end-mill, and high-precision grinding like a diamond wheel.
碳纤维增强塑料(CFRP)以其优异的力学性能被广泛应用于各个领域。通常,在模制制造后,CFRP需要额外的机械加工,如切割或研磨。作为碳纤维布的切削工具,开发了一种具有高耐磨性的金刚石涂层立铣刀。然而,毛刺或未切割的纤维很容易形成。同时,在使用砂轮的情况下,即使存在带有毛刺或未切割纤维的尖锐边缘,加工效率也很低。因此,需要开发一种能够高效实现CFRP精密加工的通用工具。本研究开发了一种由刀具和砂轮组合而成的cBN电镀立铣刀。该报告表明,所开发的工具能够像金刚石涂层立铣刀一样进行高效切削,也能够像金刚石砂轮一样进行高精度磨削。
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引用次数: 2
Experimental investigations on super-smooth polishing of strontium titanate based ceramics substrates 钛酸锶基陶瓷衬底超光滑抛光的实验研究
Q3 Engineering Pub Date : 2017-09-27 DOI: 10.1504/IJAT.2017.10007959
Q. Yan, Cao Xiao-bei, Pan Jisheng
Strontium titanate (SrTiO3) is a new type of multi-function electronic ceramic material. SrTiO3 ceramic substrates with a high dielectric constant can be obtained by non-pressurised sintering using ultrathin blanks, which result in the characteristics of thin, soft, brittle and warped. So that SrTiO3 ceramics substrates need to be polished to improve surface quality and dimensional precision before application. In this research, polish experiments with various processing parameters on the surface roughness, the material removal rate and the surface morphologies of SrTiO3 ceramic substrates were conducted. The results show that the SrTiO3 ceramic substrate with a highest quality surface was obtained in the condition: employing a brown polyurethane pad to polish the substrates at a polishing velocity of 45 r/min. Meanwhile, the slurry flow rate, the concentration of the polishing slurry and the polishing pressure were 20 ml/min, 4 wt% and 15.043 kPa, respectively, which rates with an overall and a partial surface roughness of Ra 0.01 µm and Ra 4 nm, respectively. While some new micro-scratches were generated on the surface of the SrTiO3 ceramics substrate in the polishing process because the embedding and scratching of abrasive particle led to expose the inherent pores and grain boundaries.
钛酸锶(SrTiO3)是一种新型多功能电子陶瓷材料。采用超薄毛坯非加压烧结可获得高介电常数的SrTiO3陶瓷基片,具有薄、软、脆、翘曲等特点。因此,SrTiO3陶瓷基板在应用前需要进行抛光,以提高表面质量和尺寸精度。在本研究中,进行了不同工艺参数对SrTiO3陶瓷基板表面粗糙度、材料去除率和表面形貌的抛光实验。结果表明:采用棕色聚氨酯衬垫以45 r/min的抛光速度抛光SrTiO3陶瓷衬底,获得了表面质量最高的SrTiO3陶瓷衬底;抛光液流速为20 ml/min,抛光液浓度为4 wt%,抛光压力为15.043 kPa,抛光液的整体表面粗糙度为0.01µm,局部表面粗糙度为4 nm。而在抛光过程中,由于磨料颗粒的嵌埋和刮擦导致原有的孔隙和晶界暴露,在SrTiO3陶瓷基体表面产生了一些新的微划痕。
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引用次数: 1
An analytical force and surface roughness model for cylindrical grinding of brittle materials 脆性材料外圆磨削的解析力和表面粗糙度模型
Q3 Engineering Pub Date : 2017-09-27 DOI: 10.1504/IJAT.2017.10007964
Ali Zahedi, B. Azarhoushang
In this paper, an analytical approach is proposed for the modelling of ground surface and grinding forces in cylindrical grinding of ceramic materials. The model incorporates the near-actual distribution of cutting grains over the grinding wheel surface and a kinematic approach for the engagement of the grains with the workpiece surface per grinding parameters and conditions. To interpret the stochastic engagement of arbitrary grains with the workpiece, and to distinguish the dominant material removal mechanism, fracture mechanics of single-grain indentation is applied. The approach based on the fracture mechanics accounts for grain size and geometry and material properties. The results of a previously performed research on single-grain scratch tests are taken for interpreting force and workpiece surface characteristics. Without losing generality, the model was applied to a cylindrical plunge grinding of an alumina ceramic. The experiments show qualitative agreement of model predictions with the experimental force and ground workpiece topography.
本文提出了一种分析方法,用于陶瓷材料外圆磨削中磨削表面和磨削力的建模。该模型结合了砂轮表面上切削晶粒的近似实际分布,以及根据磨削参数和条件使晶粒与工件表面接合的运动学方法。为了解释任意晶粒与工件的随机啮合,并区分主要的材料去除机制,应用了单晶粒压痕的断裂力学。基于断裂力学的方法考虑了晶粒尺寸、几何形状和材料特性。采用先前进行的单晶粒划痕试验研究的结果来解释力和工件表面特性。在不失一般性的情况下,将该模型应用于氧化铝陶瓷的圆柱插磨。实验表明,模型预测与实验力和磨削工件形貌定性一致。
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引用次数: 7
Study on hardening mechanism in GH and PSHG based on classical nucleation theory 基于经典成核理论的GH和PSHG硬化机理研究
Q3 Engineering Pub Date : 2017-09-27 DOI: 10.1504/IJAT.2017.10007963
X. Shi, S. Xiu, Xiuming Zhang
Grinding hardening (GH) is a common processing method and pre-stressed hardening grinding (PSHG) is presented combined with the advantages of grinding hardening and pre-stress grinding. In order to study their hardening and transformation mechanism, the paper carried on the GH and PSHG experiments. According to the results, the hardening mechanism in GH was reanalysed through the point of classical nucleation theory. And the coupling relationship of stress, temperature and microstructure in PSHG is studied as well. The study shows: the dislocation in the grinding area compensates the negative factors of cooling speed during GH, so the hardening effect is remarkable. In PSHG, the parent-phase-hardening and strain-inducing-phase-changing due to applying pre-stress have comprehensive effect on the martensitic phase transformation in the grinding process. The characteristic of microstructure in hardening layer can be controlled by applying different pre-stress in PSHG.
磨削硬化(GH)是一种常用的加工方法,结合磨削硬化和预应力磨削的优点,提出了预应力硬化磨削(PSHG)。为了研究其硬化转变机理,进行了GH和PSHG实验。根据实验结果,从经典成核理论的角度重新分析了GH中的硬化机理。研究了PSHG中应力、温度和微观组织的耦合关系。研究表明:磨削区位错补偿了淬火过程中冷却速度的不利因素,淬火效果显著。在PSHG中,施加预应力导致的母相硬化和应变诱导相变对磨削过程中马氏体相变有综合影响。通过施加不同的预应力,可以控制硬化层的微观组织特征。
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引用次数: 0
Experimental investigation of process parameters for conductive graphite abrasive mixed EDM of WC alloy WC合金导电石墨磨料混合电火花加工工艺参数的实验研究
Q3 Engineering Pub Date : 2017-09-27 DOI: 10.1504/IJAT.2017.10007960
Jagdeep Singh, R. Sharma
The aim of current experimental investigation is to perform and study the effect of input processing parameters for abrasive mixed electrical discharge machining (PM-EDM) of tungsten carbide alloy. Mainly, four input processing parameters have been studied, i.e., pulse duration, peak current, abrasive concentration and abrasive grain size for the machinability evaluation of material removal rate and tool wear rate. In this study, graphite (C) abrasive is suspended into the dielectric fluid to make the discharging process stable and uniform, which results in improvement of process mechanism and efficiency. However, this study highlights the mathematical modelling to express the inter relationship between input processing and performance characteristics with the help of response surface methodology (RSM). Results from the study shows the positive influence of graphite abrasive used for PM-EDM of WC alloy with reduction in tool wear rate (5.22%) along with the achievement of significant material removal rate (6.74%).
本实验研究的目的是对硬质合金磨料混合放电加工(PM-EDM)中输入工艺参数的影响进行研究。主要研究了四个输入加工参数,即脉冲持续时间、峰值电流、磨料浓度和磨料粒度,用于材料去除率和刀具磨损率的可加工性评估。在本研究中,将石墨(C)磨料悬浮在电介质流体中,使放电过程稳定均匀,从而改善了放电机理和效率。然而,本研究强调了数学建模,以借助响应面方法(RSM)来表达输入处理和性能特征之间的相互关系。研究结果表明,石墨磨料用于WC合金的PM-EDM对降低刀具磨损率(5.22%)以及实现显著的材料去除率(6.74%)具有积极影响。
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引用次数: 5
Design of dimpled engineering surfaces for improving lubrication performance in rolling-sliding contacts 为改善滚动-滑动接触润滑性能而设计的凹痕工程表面
Q3 Engineering Pub Date : 2017-09-27 DOI: 10.1504/IJAT.2017.10007961
F. Hashimoto, R. Zhou
Functional performance depends largely on the surface characteristics of critical components. This paper describes the design of dimpled engineering surfaces and the fabrication of micro-patterns on steel samples. The designed engineering surfaces are analysed and evaluated in terms of their mixed EHL film thicknesses and pressure distributions in the elliptical Hertzian contact zone.
功能性能在很大程度上取决于关键部件的表面特性。本文介绍了工程表面的设计和钢样品微图案的制作。对所设计的工程表面的混合EHL膜厚度和椭圆赫兹接触区的压力分布进行了分析和评价。
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引用次数: 2
Study on the surface micro-topography in pre-stressed dry grinding process 预应力干磨过程中表面微形貌的研究
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.10010191
Yansheng Deng, X. Shi, S. Xiu, Minghe Liu
To study the surface micro-topography in pre-stressed dry grinding process, the single grain cutting simulations were carried out in DEFORM-3D, besides, dry grinding experiments were conducted. The residual stress, groove depth and pile-up height were analysed in the simulations. The surface roughness was measured, and micro-surface topography was observed by SEM in the experiments. The results indicated that the application of pre-stress is beneficial to generate more compressive stress, which is beneficial to restrain the generation of surface micro-cracks. Pre-stress can reduce the pile-up height. When pre-stress is within a lower range, the groove depth decreases with pre-stress increasing, however, once pre-stress overcomes a certain value, surface fold appears and surface roughness increases instead. The influence rules of the cutting depth and feeding speed on surface micro-topography in pre-stressed dry grinding process are consistent with them in the traditional grinding process.
为了研究预应力干磨过程中的表面微观形貌,在DEFORM-3D中进行了单晶粒切削模拟,并进行了干磨实验。模拟分析了残余应力、槽深和堆积高度。实验中测量了表面粗糙度,并用扫描电镜观察了微表面形貌。结果表明:施加预应力有利于产生较大的压应力,有利于抑制表面微裂纹的产生;预应力可以降低堆垛高度。在较低的预应力范围内,沟槽深度随着预应力的增大而减小,但一旦预应力超过一定值,表面褶皱出现,表面粗糙度反而增大。预应力干磨过程中切削深度和进给速度对表面微形貌的影响规律与传统磨削过程一致。
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引用次数: 1
Wheel lift-off in creep-feed grinding: thermal damage, power surge, chip thickness and optimisation 爬行进给磨削中的砂轮升降:热损伤,功率浪涌,切屑厚度和优化
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.089287
R. Dražumerič, Jeffrey Badger, P. Krajnik
An investigation is made into the phenomenon of early lift-off in creep-feed grinding, where the wheel lifts away from the workpiece before reaching the end of cut. In single-pass operations, early lift-off can result in thermal damage. In multi-pass operations, there is a surge in material-removal rate just before lift-off, which can result in thermal damage and excess wheel wear. This study examines the current inadequate methods of dealing with lift-off. It then develops a geometric and kinematic model for analysing the lift-off phenomenon. It finally proposes a thermal-model-based optimisation method for achieving a constant maximum surface temperature, resulting in shorter cycle times and less risk of thermal damage. The power-surge model is validated experimentally in diamond grinding of tungsten-carbide rotary tools.
研究了蠕变进给磨削中砂轮在到达切削终点前离工件较远的起升现象。在单道作业中,过早的起离可能会导致热损伤。在多道次作业中,在起吊前的材料去除率会激增,这可能会导致热损伤和轮毂过度磨损。本研究考察了目前处理升空的不适当方法。然后建立了一个几何和运动学模型来分析升空现象。最后提出了一种基于热模型的优化方法,以实现恒定的最大表面温度,从而缩短循环时间并降低热损伤的风险。在碳化钨旋转刀具的金刚石磨削实验中验证了功率浪涌模型。
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引用次数: 1
Effects of grinding process parameters on the surface topography of PCBN cutting inserts 磨削工艺参数对PCBN刀片表面形貌的影响
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.10010195
B. Azarhoushang, T. Stehlé, Heike Kitzig-Frank, H. Möhring
PCBN as a cutting tool material is a proper choice for machining difficult-to-cut materials. This is due to its hardness, chemical stability and toughness. The surface quality of PCBN tools, which are commonly ground with diamond wheels, strongly depends on the grinding parameters. The cutting forces, temperature, loading and wear of the grinding wheel influence the quality of the ground PCBN surface. The effects of cutting parameters on the cutting forces, roughness and loading of the grinding wheel during plunge face grinding of PCBN inserts are studied in this work. It was found that increasing the cutting speed from 20 to 40 m/s can decrease the cutting forces and surface roughness up to 20% and 30%, respectively. Additionally, the amount of oversize in roughing and the roughing parameters have a significant influence on the induced cutting forces in the finishing stage and the surface quality of the ground PCBN inserts.
PCBN作为刀具材料是加工难切削材料的理想选择。这是由于它的硬度、化学稳定性和韧性。PCBN刀具通常采用金刚石砂轮磨削,其表面质量很大程度上取决于磨削参数。砂轮的切削力、温度、载荷和磨损影响PCBN磨削表面的质量。研究了PCBN刀片切入面磨削过程中切削参数对切削力、粗糙度和砂轮载荷的影响。结果表明,将切削速度从20 ~ 40 m/s提高,可使切削力和表面粗糙度分别降低20%和30%。粗加工中过大尺寸的数量和粗加工参数对精加工阶段的诱导切削力和磨削后的PCBN刀片的表面质量有显著影响。
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引用次数: 5
An experimental study of the particle velocities in abrasive waterjets 磨料水射流中粒子速度的实验研究
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.10010199
K. Thongkaew, Jun Wang
An experimental study using particle image velocimetry (PIV) and laser induced fluorescence (LIF) techniques is presented to examine the particle flow characteristics inside the high velocity abrasive waterjet (AWJ) and assess the capability of this measurement technique. Although the particle velocity is found to increase with an increase in water pressure, the velocity of particles on the jet centreline decreases while that at the jet edge increases as the jet flows downstream within 40 mm distance from the nozzle exit considered in this study. It is also shown that particles rotate while moving downstream from the nozzle exit. While these particle flow characteristics may be anticipated from theoretical understanding, it confirms that the capability of this technique is not only able to measure the particle velocities, but also observe the particle trajectory in high velocity flows. The measured particle velocity data are then used to assess the applicability of a previously developed particle velocity model for low water pressures. It is found that the model can equally give adequate predictions of particles velocities in AWJ for relatively low water pressures of within 20 MPa.
采用粒子图像测速(PIV)和激光诱导荧光(LIF)技术对高速磨料水射流内部的粒子流动特性进行了实验研究,并对该测量技术的性能进行了评价。虽然发现颗粒速度随着水压的增加而增加,但在本文所考虑的距离喷管出口40mm范围内,射流向下游流动时,射流中心线颗粒速度减小,射流边缘颗粒速度增大。还表明,颗粒在从喷嘴出口向下游移动时发生旋转。虽然这些颗粒流动特性可以从理论上预测,但它证实了该技术的能力不仅能够测量颗粒速度,而且可以观察高速流动中的颗粒轨迹。测量的颗粒速度数据随后用于评估先前开发的低水压颗粒速度模型的适用性。结果表明,该模型能较好地预测20 MPa内较低水压下水射流中的颗粒速度。
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引用次数: 2
期刊
International Journal of Abrasive Technology
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