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Modelling of the micro-grinding process considering the grinding tool topography 考虑磨削工具形貌的微磨削过程建模
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.10010200
M. Kadivar, Ali Zahedi, B. Azarhoushang, P. Krajnik
The micro topography of the grinding tool has a considerable influence on the cutting forces and temperature as well as the tool wear. This paper addresses an analytical modelling of the micro-grinding process based on the real tool topography and kinematic modelling of the cutting-edgeworkpiece interactions. An approximate shape of the abrasive grains and their distribution is obtained from the confocal images, which are taken from the tool surface - determining the grain height protrusion and the probability density function of the grains. To determine the grinding forces, a transient kinematic approach is developed. In this method, the individual grit interaction with the workpiece is extended to the whole cutting zone in the peripheral flank grinding operation. Hence a predictive model of cutting forces and surface roughness in micro grinding of titanium grade 5 is developed. Finally, the simulated forces and surface roughness are validated by the experimental results.
磨削刀具的微观形貌对切削力、切削温度以及刀具的磨损有相当大的影响。基于真实刀具形貌和刀具刃口与工件相互作用的运动学建模,建立了微磨削过程的解析模型。从刀具表面的共聚焦图像中得到磨料颗粒的近似形状及其分布,确定了颗粒的高度、突出度和颗粒的概率密度函数。为了确定磨削力,提出了一种瞬态运动学方法。在这种方法中,单个砂粒与工件的相互作用扩展到整个切削区域。在此基础上,建立了5级钛微磨削切削力与表面粗糙度的预测模型。最后,用实验结果验证了模拟力和表面粗糙度的正确性。
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引用次数: 6
The effects of temperature curves on the diamond/Ni-Cr interfacial properties in high-frequency induction brazing 高频感应钎焊中温度曲线对金刚石/Ni-Cr界面性能的影响
Q3 Engineering Pub Date : 2017-01-01 DOI: 10.1504/IJAT.2017.10010198
G. Huang, M. Zhang, Hua Guo, Xipeng Xu
The present study alters the temperature characteristics during high-frequency induction brazing of diamond grits and investigates their effects on the properties of the diamond/brazing alloy interface. The high-frequency induction brazing was conducted in a vacuum using Ni-Cr as active filler alloy. An active temperature range was identified for the brazing of high-quality diamond tools. This temperature range, coupled with long heating time, favours the wetting of filler alloy to diamonds, and the chemical reactions and element diffusion at the diamond/alloy interface, but reduces the static compressive strength of the diamonds. If the temperature is slowly raised, the protrusion height and location of brazed diamonds can be more precisely controlled. Brazed diamonds with 30%-50% protrusion are optimal for cutting.
研究了金刚石磨粒高频感应钎焊过程中温度特性的变化及其对金刚石/钎焊合金界面性能的影响。采用镍铬合金作为活性钎料,在真空条件下进行高频感应钎焊。确定了高质量金刚石工具钎焊的有效温度范围。该温度范围加上较长的加热时间有利于填充合金对金刚石的润湿,有利于金刚石/合金界面的化学反应和元素扩散,但降低了金刚石的静态抗压强度。如果慢慢升高温度,则可以更精确地控制钎焊金刚石的突出高度和位置。钎焊金刚石的突出度为30%-50%,最适合切割。
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引用次数: 5
Characterisation of the tool wear during ductile polishing of ceramic tiles using morphological space 用形态空间表征陶瓷球墨抛光过程中刀具的磨损
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078293
F. Sousa, J. Seewig, R. M. Nascimento, C. Chiamulera, O. E. Alarcon, W. L. Weingärtner
The present work is focused on the wear of the abrasive tools during the industrial polishing process of porcelain stoneware tiles, aiming to extend the validity of using morphological space to quantify the wear when very fine abrasive tools are used. In such morphological space, the horizontal and vertical axes are respectively the skewness (Sk) and the kurtosis (K) of the distribution of heights taken from several surface profiles. Despite the existence of an intrinsic interaction between Sk and K, the approach enables the sequence of geometrical changes suffered by the fickert surface to be quantitatively evaluated. The experimental points obtained were nearly aligned and with a negative slope, just as expected for abrasive wear. Implausibly, the results for fine abrasive fickerts was much more scattered than for those with coarse abrasive particles found in literature.
本研究以陶瓷陶瓷砖工业抛光过程中磨具的磨损为研究对象,旨在拓展利用形态空间量化极细磨具磨损的有效性。在该形态空间中,横轴和纵轴分别是取自若干表面剖面的高度分布的偏度(Sk)和峰度(K)。尽管Sk和K之间存在固有的相互作用,但该方法可以定量评估菲克特表面遭受的几何变化序列。得到的实验点几乎对齐,并具有负斜率,正如预期的磨料磨损。令人难以置信的是,细粒磨料颗粒的结果比文献中发现的粗粒磨料颗粒要分散得多。
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引用次数: 0
Some studies on three-body abrasive wear behaviour of hardfaced steel alloy for agricultural plough tool application 农用犁具用硬面钢合金三体磨粒磨损性能研究
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078287
A. R. Annappa, S. Basavarajappa
The influences of hardfacing deposit and deep cryogenic treatment on three-body abrasive wear behaviour of AISI 1013 steel were studied. The three-body abrasive wear tests were carried out using the dry sand/rubber wheel test rig as per ASTM G65 standard. Hardfacing was done by manual arc welding using ZEDALLOY VB hardfacing electrode. The deep cryogenic treatment was carried by using liquid nitrogen temperature at −196°C. The applied load, sliding velocity and sliding distance were considered as process parameters. Experimental results reveal that the hardfacing deposit showed the highest abrasive wear resistance as compared to deep cryotreated material. Worn-out surface observation by SEM witnessed same behaviour. The nature of material removal was microploughing or microcutting depending on the attack angle, due to cracks formed on the surface of material.
研究堆焊堆积物和深冷处理对AISI 1013钢三体磨粒磨损性能的影响。按照ASTM G65标准,采用干砂/橡胶轮试验台进行三体磨料磨损试验。堆焊采用ZEDALLOY VB堆焊焊条进行手工电弧焊。采用- 196℃的液氮进行深冷处理。以载荷、滑动速度和滑动距离为工艺参数。实验结果表明,堆焊层的耐磨性优于深冷处理材料。通过扫描电镜对磨损表面的观察也发现了相同的行为。由于材料表面形成裂纹,根据攻角的不同,材料去除的性质是微耕或微切削。
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引用次数: 1
Prohibiting the loading of grinding tools via infiltration 禁止通过渗透加载磨具
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078296
B. Azarhoushang
The produced chips in the grinding process may load the pores and cavities between the cutting grains. The loading of the grinding tool reduces the amount of the transported coolant to the contact zone and simultaneously increases the induced heath by friction in the cutting zone. Hence, increased grinding forces and temperature, surface roughness and wear of the cutting grains are the consequences of a loaded grinding tool. Infiltration of the grinding tool is one of the effective methods to reduce loading. The effects of infiltration have been studied for the first time in this research on various vitrified bonded grinding wheels with different grain materials, grit sizes, porosity and hardness. Better surface quality and longer dressing intervals are the main results of the infiltration of the grinding tools.
在磨削过程中产生的切屑可能会在切削晶粒之间产生孔洞。磨具的加载减少了输送到接触区冷却液的量,同时增加了切削区摩擦引起的健康。因此,增加的磨削力和温度,表面粗糙度和切削晶粒的磨损是负载磨削工具的后果。磨具渗滤是减少载荷的有效方法之一。本文首次对不同晶粒材料、粒度、孔隙率和硬度的陶瓷结合剂砂轮进行了入渗影响研究。磨具渗透的主要结果是表面质量的提高和修整间隔的延长。
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引用次数: 0
Grinding force performance with different types of grinding fluids based on a semi-empirical force model 基于半经验力模型的不同类型磨削液的磨削力性能
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078280
Guoxu Yin, I. Marinescu, M. C. Weismiller
In the present paper, a semi-empirical grinding force model is developed combined with the achievements of previous researchers by composing effects of normal and tangential grinding forces in two main parts respectively: cutting force and sliding force. This model is used to predict the total normal and tangential force in the surface grinding. These force components were expressed in terms of the grinding process parameters such as wheel speed, workpiece feed rate, width of the workpiece and depth of cut. There are four unknown coefficients in each equation which can be determined by experiment results at specific conditions with the variations of grinding process parameters. Four different water-based grinding fluids were tested for different specific grinding conditions. The calculated normal and tangential grinding results are compared with the experimental ones. To have a better agreement with experiment data, shallow grinding condition is chosen to obtain the modified model.
本文结合前人研究成果,将法向磨削力和切向磨削力的作用分别纳入切削力和滑动力两个主要部分,建立了半经验磨削力模型。该模型用于预测曲面磨削过程中总法向力和切向力。这些力分量用砂轮速度、工件进给速度、工件宽度和切削深度等磨削工艺参数表示。每个方程中有4个未知系数,它们可以根据磨削工艺参数的变化在特定条件下的实验结果确定。在不同的磨削条件下,对四种不同的水基磨削液进行了试验。计算的法向和切向磨削结果与实验结果进行了比较。为了与实验数据更吻合,选择浅磨条件得到修正模型。
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引用次数: 2
A study of multiobjective parametric optimisation of electric discharge diamond cut-off grinding of Inconel 718 英科乃尔718电火花金刚石切割磨削多目标参数优化研究
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078281
D. Unune, H. Mali
Hybrid machining techniques are becoming more and more popular for machining of difficult-to-cut materials. This paper presents an approach for the optimisation of electric discharge diamond cut-off grinding of Inconel 718 with multiple performance characteristics based on the Taguchi orthogonal array with grey relational analysis. In this study, the machining parameters namely, wheel speed, current, pulse-on-time, and duty factor are optimised for performance characteristics, i.e., material removal rate and surface roughness. The optimal machining parameters are determined by the Grey relational grade as the performance index. The research result identifies significant machining parameters and their effects on process performance. The confirmation experiments have been conducted to verify the optimal process conditions. Experimental results show that the performance of process improved effectively through this approach.
混合加工技术在难加工材料的加工中越来越受欢迎。提出了一种基于田口正交阵和灰色关联分析的多种性能特征的英科镍铁合金718电火花切割磨削优化方法。在这项研究中,加工参数,即车轮速度,电流,脉冲启动时间和占空因子,优化了性能特征,即材料去除率和表面粗糙度。以灰色关联度作为性能指标确定最优加工参数。研究结果确定了重要的加工参数及其对工艺性能的影响。通过实验验证了最佳工艺条件。实验结果表明,该方法有效地提高了过程的性能。
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引用次数: 7
Modelling and multi-objective optimisation of EDDG process using hybrid ANN-GA approach 基于混合神经网络-遗传算法的EDDG过程建模与多目标优化
Q3 Engineering Pub Date : 2016-08-16 DOI: 10.1504/IJAT.2016.078294
P. Shrivastava, A. K. Dubey
It has been found that wheel wear rate (WWR) and surface finish is adversely affected in order to improve the material removal rate (MRR) in electrical discharge diamond grinding (EDDG) process. Therefore, simultaneous optimisation of above three responses is always desired. This research paper presents the modelling and multi-objective optimisation of EDDG using AI-based hybrid ANN-GA approach. The effect of wheel grit size has also been considered along with electrical parameters such as peak current, pulse-on time and pulse-off time. The significant control parameters for different responses have been found and effect of their variation has been discussed. The developed ANN models for different responses have been found reliable with negligible prediction errors. The optimisation results show considerable improvement of 97% in MRR with marginal increase in WWR and surface roughness.
在电火花金刚石磨削(EDDG)过程中,为了提高材料去除率,砂轮磨损率(WWR)和表面光洁度会受到不利影响。因此,总是需要同时优化以上三个响应。本文采用基于人工智能的混合ANN-GA方法对EDDG进行建模和多目标优化。同时还考虑了砂轮粒度与峰值电流、脉冲接通时间和脉冲关闭时间等电气参数的影响。找到了不同反应的显著控制参数,并讨论了其变化的影响。对不同的响应所建立的人工神经网络模型已被证明是可靠的,预测误差可以忽略不计。优化结果表明,MRR显著提高97%,而WWR和表面粗糙度略有增加。
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引用次数: 8
Effect of process parameters on the surface roughness generated on graphite laced GFRP composite by AWJ machining AWJ加工工艺参数对石墨复合材料表面粗糙度的影响
Q3 Engineering Pub Date : 2016-01-01 DOI: 10.1504/IJAT.2016.10002374
D. Doreswamy, Basit Eqbal, Siddaram Sangolagi, A. Devineni
In this research paper, the effect of abrasive water jet (AWJ) machining process parameters such as jet operating pressure, feed rate, abrasive concentration and standoff distance (SOD) on the surface roughness produced during machining of graphite mixed glass fibre reinforced polymer (GFRP) composite is investigated. Experiments were conducted using Taguchi's L27 orthogonal array design and the process parameters were optimised to obtain high surface finish. Experimental data were analysed using analysis of variance (ANOVA) which shows that the surface roughness decreased by 15.90% and increased by 9.22% for the increase in operating pressure and SOD respectively. Also, regression model is developed to predict the surface roughness and found that the predicted values are in close agreement with the experimental values (error 6.57%).
本文研究了磨料水射流(AWJ)加工工艺参数(射流操作压力、进给量、磨料浓度和超氧化物歧化酶(SOD))对石墨混合玻璃纤维增强聚合物(GFRP)复合材料加工过程中表面粗糙度的影响。采用田口L27正交设计进行了实验,并对工艺参数进行了优化,获得了较高的表面光洁度。采用方差分析(ANOVA)对实验数据进行分析,结果表明,操作压力和SOD的增加分别使表面粗糙度降低了15.90%和9.22%。建立回归模型对表面粗糙度进行预测,结果表明,预测值与实验值吻合较好,误差为6.57%。
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引用次数: 4
Magnetorheological finishing with tangential magnetic fields formed by the rotation of a magnetic pole 由磁极旋转形成的切向磁场的磁流变整理
Q3 Engineering Pub Date : 2016-01-01 DOI: 10.1504/IJAT.2016.10002377
Yuanyang H. Peng, Pan Jisheng, Q. Yan
Based on the magnetorheological (MR) effect, this research proposes a kind of magnetorheological finishing (MRF) in tangential magnetic fields formed by the rotation of magnetic poles in order to achieved realtime adjustment of MR polishing pads. In this paper, monocrystalline silicon was utilised to investigate the plane polishing characteristics based on the magnetorheology in single-point dynamic magnetic fields under different process conditions. Results showed that favourable polishing effects were obtained when silicon carbide abrasive was used to polish the workpieces for 50 to 70 min with the tangential magnetic fields being 5 mm and the machining gap being 1.1 mm. Afterwards, strontium titanate ceramic substrate, monocrystalline silicon and monocrystal 6H-SiC were polished for 50 min using this technology. It was found that the surface roughness Ra of this three materials were reduced from 0.45 to 0.11 µm, from 400 to 7 nm and from 70 to 9 nm, respectively.
本研究基于磁流变效应,提出了一种在磁极旋转形成的切向磁场中进行磁流变抛光的方法,以实现磁流变抛光垫的实时调节。本文以单晶硅为研究对象,研究了不同工艺条件下单点动态磁场下的平面抛光特性。结果表明,在切向磁场为5 mm、加工间隙为1.1 mm的条件下,采用碳化硅磨料对工件进行抛光50 ~ 70 min,可获得较好的抛光效果。然后对钛酸锶陶瓷衬底、单晶硅和单晶6H-SiC进行50min的抛光处理。结果表明,三种材料的表面粗糙度Ra分别从0.45 μ m降低到0.11 μ m,从400 nm降低到7 nm,从70 nm降低到9 nm。
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引用次数: 5
期刊
International Journal of Abrasive Technology
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