Pub Date : 2022-11-02DOI: 10.1080/10910344.2023.2180752
Hanie Ghanbari, M. Ketabchi, Esmaeil Damavandi
Abstract The objective of the present study is to investigate the effect of chemical composition and microstructure on machinability, mechanical properties, and crack growth of GG-20 gray cast iron for brake drum application. The effects of a reduction in C and Si on microstructural parameters such as type, size, and aspect ratio of graphite particles, interlamellar spacing of pearlite, and the presence of MnS were investigated. In the following, the effect of different microstructures on mechanical properties and machinability of cast iron were studied. The fracture surface, crack growth, worn surface, chip formation and wear on cutting tools have been studied as well. The results showed that both tensile strength and hardness increased, and the machinability reduced by decreasing C and Si. By reducing the C content from 3.4% to 3.2%, the maximum hardness value and tensile strength were obtained to be 207HB and 286 MPa, respectively. Moreover, the Ra and Rz values were increased to 4.3 μm and 25.8 μm, respectively. With an increase in the length of graphite flakes, the distance between microcracks on the machined chips decreased. In the sample with the lower hardness value, delamination occurred extensively and led to the disappearance of cracks and pores on the worn surface.
{"title":"Effect of chemical composition and microstructure on the crack growth and machinability of GG20 gray cast iron for brake drum application","authors":"Hanie Ghanbari, M. Ketabchi, Esmaeil Damavandi","doi":"10.1080/10910344.2023.2180752","DOIUrl":"https://doi.org/10.1080/10910344.2023.2180752","url":null,"abstract":"Abstract The objective of the present study is to investigate the effect of chemical composition and microstructure on machinability, mechanical properties, and crack growth of GG-20 gray cast iron for brake drum application. The effects of a reduction in C and Si on microstructural parameters such as type, size, and aspect ratio of graphite particles, interlamellar spacing of pearlite, and the presence of MnS were investigated. In the following, the effect of different microstructures on mechanical properties and machinability of cast iron were studied. The fracture surface, crack growth, worn surface, chip formation and wear on cutting tools have been studied as well. The results showed that both tensile strength and hardness increased, and the machinability reduced by decreasing C and Si. By reducing the C content from 3.4% to 3.2%, the maximum hardness value and tensile strength were obtained to be 207HB and 286 MPa, respectively. Moreover, the Ra and Rz values were increased to 4.3 μm and 25.8 μm, respectively. With an increase in the length of graphite flakes, the distance between microcracks on the machined chips decreased. In the sample with the lower hardness value, delamination occurred extensively and led to the disappearance of cracks and pores on the worn surface.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"977 - 1002"},"PeriodicalIF":2.7,"publicationDate":"2022-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46567213","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-09-03DOI: 10.1080/10910344.2023.2181089
Chen Zhang, Xiaoxue Wang, V. Silberschmidt
Abstract Carbon-fiber-reinforced plastic (CFRP) composites are intensively used in aircraft and aerospace industry thanks to their superior properties. Comparing to the conventional drilling (CD), vibration-assisted drilling (VAD) is a novel machining technique suitable for drilling CFRP. Still, multi-mode excitations with elliptical locus and low vibration performance limit the applications of current VAD schemes for CFRP. To overcome these limitations and improve the overall performance, an innovative longitudinal-torsional complex-mode ultrasonic vibration-assisted actuator with single excitation and an elliptical locus is presented employing a piezoelectric transducer and a stepped horn with spiral grooves. The proposed actuator is specially designed to deliver elliptical vibration and assure high vibration performance of a tool tip. Analysis of the actuation mechanism for the longitudinal-torsional composite vibration mode is discussed, and its simplified model is developed. A detailed design process of this actuator is given. Its vibration characteristics are verified with both finite-element simulation and experimental modal analysis using a swept sine test. It is demonstrated the developed prototype achieved longitudinal-torsional elliptical vibration. To validate the machining performance of the actuator, two groups of drilling experiments were performed. These indicate that the proposed actuator is capable of drilling CFRP with improved machining performance.
{"title":"Longitudinal-torsional complex-mode ultrasonic actuator for vibration-assisted drilling of CFRP","authors":"Chen Zhang, Xiaoxue Wang, V. Silberschmidt","doi":"10.1080/10910344.2023.2181089","DOIUrl":"https://doi.org/10.1080/10910344.2023.2181089","url":null,"abstract":"Abstract Carbon-fiber-reinforced plastic (CFRP) composites are intensively used in aircraft and aerospace industry thanks to their superior properties. Comparing to the conventional drilling (CD), vibration-assisted drilling (VAD) is a novel machining technique suitable for drilling CFRP. Still, multi-mode excitations with elliptical locus and low vibration performance limit the applications of current VAD schemes for CFRP. To overcome these limitations and improve the overall performance, an innovative longitudinal-torsional complex-mode ultrasonic vibration-assisted actuator with single excitation and an elliptical locus is presented employing a piezoelectric transducer and a stepped horn with spiral grooves. The proposed actuator is specially designed to deliver elliptical vibration and assure high vibration performance of a tool tip. Analysis of the actuation mechanism for the longitudinal-torsional composite vibration mode is discussed, and its simplified model is developed. A detailed design process of this actuator is given. Its vibration characteristics are verified with both finite-element simulation and experimental modal analysis using a swept sine test. It is demonstrated the developed prototype achieved longitudinal-torsional elliptical vibration. To validate the machining performance of the actuator, two groups of drilling experiments were performed. These indicate that the proposed actuator is capable of drilling CFRP with improved machining performance.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"894 - 921"},"PeriodicalIF":2.7,"publicationDate":"2022-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42976903","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-09-03DOI: 10.1080/10910344.2023.2180750
A. Sahu, S. Mahapatra
Abstract Recently, additive manufacturing based rapid tooling (RT) is gaining popularity in manufacturing industries because tool fabrication time and cost can be substantially reduced. In this regard, an experimental investigation is made to explore the machining performance of AlSi10Mg tool electrode manufactured through direct metal laser sintering and compared with commonly used copper and graphite electrodes in electro-discharge machining (EDM) of titanium alloy work piece. The influence of EDM variables on performance measures like material removal rate, tool wear rate, arithmetic mean surface roughness, surface crack density, white layer thickness and microhardness has been analyzed. The machined surface generated with the usage of different electrodes is inspected by scanning electron microscopy to study the surface integrity. It is observed that superior surface integrity can be attained utilizing AlSi10Mg DMLS electrode at lower setting of machining parameters. Energy dispersion X-ray spectroscopy analysis reveals that transfer of tool electrode elements onto the machined surface occurs along with increase in percentage of carbon and oxygen on the machined surface. From the X-ray diffraction analysis, it is found that metal carbides like titanium carbide and vanadium carbide are formed on the machined surface leading to increase in microhardness of the surface.
{"title":"Performance analysis of EDM electrode manufactured by direct metal laser sintering during machining of titanium alloy (Ti6Al4V)","authors":"A. Sahu, S. Mahapatra","doi":"10.1080/10910344.2023.2180750","DOIUrl":"https://doi.org/10.1080/10910344.2023.2180750","url":null,"abstract":"Abstract Recently, additive manufacturing based rapid tooling (RT) is gaining popularity in manufacturing industries because tool fabrication time and cost can be substantially reduced. In this regard, an experimental investigation is made to explore the machining performance of AlSi10Mg tool electrode manufactured through direct metal laser sintering and compared with commonly used copper and graphite electrodes in electro-discharge machining (EDM) of titanium alloy work piece. The influence of EDM variables on performance measures like material removal rate, tool wear rate, arithmetic mean surface roughness, surface crack density, white layer thickness and microhardness has been analyzed. The machined surface generated with the usage of different electrodes is inspected by scanning electron microscopy to study the surface integrity. It is observed that superior surface integrity can be attained utilizing AlSi10Mg DMLS electrode at lower setting of machining parameters. Energy dispersion X-ray spectroscopy analysis reveals that transfer of tool electrode elements onto the machined surface occurs along with increase in percentage of carbon and oxygen on the machined surface. From the X-ray diffraction analysis, it is found that metal carbides like titanium carbide and vanadium carbide are formed on the machined surface leading to increase in microhardness of the surface.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"858 - 893"},"PeriodicalIF":2.7,"publicationDate":"2022-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49607280","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-09-03DOI: 10.1080/10910344.2023.2180749
M. Dhananchezian
Abstract During cutting operations, cutting fluids increase heat carrying capacity from the cutting area and reduce friction at the chip-tool interface. It also offers benefits like favorable chip form, enhancement in the finish of product and tool life, lower cutting forces and power consumption during any cutting operations. But the inadequate application of cutting fluids and disposal creates several technical and environmental problems. So, due to the high demand for proper cooling and lubrication, many researchers are keen on cooling using cryogenic fluids. In this, liquid nitrogen is recognized as an effective cooling agent and a better lubricant as a cutting fluid during cutting. Beneficial outcomes are reduced insert wear rate, machined surface roughness, machining forces, power consumption, enhanced tool life and favorable form of chips with liquid nitrogen cooling through controlling the temperature at heat generation zones and thereby reduced adhesion at inter surfaces. This paper reviews the various cryogenic cooling approaches using liquid nitrogen during turning Ti-6Al-4V alloy. The features of existing liquid nitrogen approaches are compared based on the machining performance, and directions for further research are recommended.
{"title":"A review on performance evaluation of liquid nitrogen as coolant in turning Ti-6Al-4V alloy","authors":"M. Dhananchezian","doi":"10.1080/10910344.2023.2180749","DOIUrl":"https://doi.org/10.1080/10910344.2023.2180749","url":null,"abstract":"Abstract During cutting operations, cutting fluids increase heat carrying capacity from the cutting area and reduce friction at the chip-tool interface. It also offers benefits like favorable chip form, enhancement in the finish of product and tool life, lower cutting forces and power consumption during any cutting operations. But the inadequate application of cutting fluids and disposal creates several technical and environmental problems. So, due to the high demand for proper cooling and lubrication, many researchers are keen on cooling using cryogenic fluids. In this, liquid nitrogen is recognized as an effective cooling agent and a better lubricant as a cutting fluid during cutting. Beneficial outcomes are reduced insert wear rate, machined surface roughness, machining forces, power consumption, enhanced tool life and favorable form of chips with liquid nitrogen cooling through controlling the temperature at heat generation zones and thereby reduced adhesion at inter surfaces. This paper reviews the various cryogenic cooling approaches using liquid nitrogen during turning Ti-6Al-4V alloy. The features of existing liquid nitrogen approaches are compared based on the machining performance, and directions for further research are recommended.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"701 - 857"},"PeriodicalIF":2.7,"publicationDate":"2022-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45866388","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Background: Functional constipation (FC) and irritable bowel syndrome constipation type (IBS-C) share many similarities, and it remains unknown whether they are distinct entities or part of the same spectrum of disease. Magnetic resonance imaging (MRI) allows quantification of intraluminal fecal volume. We hypothesized that colonic volumes of patients with FC would be larger than those of patients with IBS-C, and that both patient groups would have larger colonic volumes than healthy controls (HC).
Methods: Based on validated questionnaires, three groups of participants were classified into FC (n = 13), IBS-C (n = 10), and HC (n = 19). The colonic volume of each subject was determined by MRI. Stool consistency was described by the Bristol stool scale and colonic transit times were assessed with radiopaque makers.
Key results: Overall, total colonic volumes were different in the three groups, HC (median 629 ml, interquartile range (IQR)(562-868)), FC (864 ml, IQR(742-940)), and IBS-C (520 ml IQR(489-593)) (p = 0.001). Patients with IBS-C had lower colonic volumes than patients with FC (p = 0.001) and HC (p = 0.019), but there was no difference between FC and HC (p = 0.10). Stool consistency was similar in the two patient groups, but patients with FC had longer colonic transit time than those with IBS-C (117.6 h versus 43.2 h, p = 0.019).
Conclusion: Patients with IBS-C have lower total colonic volumes and shorter colonic transit times than patients with FC. Future studies are needed to confirm that colonic volume allows objective distinction between the two conditions.
背景：功能性便秘（FC）和肠易激综合征便秘型（IBS-C）有许多相似之处，但它们是不同的疾病实体还是属于同一疾病谱仍是未知数。磁共振成像（MRI）可对肠腔内粪便体积进行量化。我们假设 FC 患者的结肠容积大于 IBS-C 患者，而且两组患者的结肠容积均大于健康对照组（HC）：方法： 根据有效的调查问卷，将三组受试者分为 FC 组（13 人）、IBS-C 组（10 人）和 HC 组（19 人）。每个受试者的结肠容积由核磁共振成像测定。粪便稠度用布里斯托尔粪便量表进行描述，结肠通过时间用不透射线标记物进行评估：总体而言，HC 组（中位数为 629 毫升，四分位数间距 (IQR)(562-868)）、FC 组（864 毫升，四分位数间距 (IQR)(742-940)）和 IBS-C 组（520 毫升，四分位数间距 (IQR)(489-593)）三组患者的结肠总容量不同（P = 0.001）。IBS-C 患者的结肠容积低于 FC 患者（p = 0.001）和 HC 患者（p = 0.019），但 FC 和 HC 患者之间没有差异（p = 0.10）。两组患者的粪便稠度相似，但 FC 患者的结肠通过时间比 IBS-C 患者长（117.6 小时对 43.2 小时，p = 0.019）：结论：与 FC 患者相比，IBS-C 患者的结肠总容量较小，结肠转运时间较短。结论：与 FC 患者相比，IBS-C 患者的结肠总容积较小，结肠转运时间较短。未来的研究需要证实结肠容积能够客观地区分这两种情况。
{"title":"Colonic volume in patients with functional constipation or irritable bowel syndrome determined by magnetic resonance imaging.","authors":"Mette Winther Klinge, Klaus Krogh, Esben Bolvig Mark, Asbjørn Mohr Drewes, Lau Brix, Christin Isaksen, Milda Dedelaite, Jens Brøndum Frøkjaer, Lotte Vinskov Fynne","doi":"10.1111/nmo.14374","DOIUrl":"10.1111/nmo.14374","url":null,"abstract":"<p><strong>Background: </strong>Functional constipation (FC) and irritable bowel syndrome constipation type (IBS-C) share many similarities, and it remains unknown whether they are distinct entities or part of the same spectrum of disease. Magnetic resonance imaging (MRI) allows quantification of intraluminal fecal volume. We hypothesized that colonic volumes of patients with FC would be larger than those of patients with IBS-C, and that both patient groups would have larger colonic volumes than healthy controls (HC).</p><p><strong>Methods: </strong>Based on validated questionnaires, three groups of participants were classified into FC (n = 13), IBS-C (n = 10), and HC (n = 19). The colonic volume of each subject was determined by MRI. Stool consistency was described by the Bristol stool scale and colonic transit times were assessed with radiopaque makers.</p><p><strong>Key results: </strong>Overall, total colonic volumes were different in the three groups, HC (median 629 ml, interquartile range (IQR)(562-868)), FC (864 ml, IQR(742-940)), and IBS-C (520 ml IQR(489-593)) (p = 0.001). Patients with IBS-C had lower colonic volumes than patients with FC (p = 0.001) and HC (p = 0.019), but there was no difference between FC and HC (p = 0.10). Stool consistency was similar in the two patient groups, but patients with FC had longer colonic transit time than those with IBS-C (117.6 h versus 43.2 h, p = 0.019).</p><p><strong>Conclusion: </strong>Patients with IBS-C have lower total colonic volumes and shorter colonic transit times than patients with FC. Future studies are needed to confirm that colonic volume allows objective distinction between the two conditions.</p>","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"6 1","pages":"e14374"},"PeriodicalIF":3.5,"publicationDate":"2022-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9539850/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"82397580","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129990
S. Paswan, Anant Kumar Singh
Abstract A new in-situ rotary magnetorheological honing (RMRH) approach has been developed in this study to fine-finish the machined inner surface of cylindric workpieces with increased productivity and dimensional accuracy. A single in-situ honing tool is used for performing both traditional as well as magnetorheological (MR) honing. The tool is fabricated based on the designed tool through magnetostatic analysis. In this work, the final MR finished surface is achieved up to 60 nm from the original machined surface roughness of 510 nm with the expense of 40 min of traditional honing and 60 min of MR finishing. Also, the great improvement in surface waviness is confirmed through the final surface waviness is achieved as 50 nm from the initial surface waviness of 1460 nm. The improvement in circularity is confirmed through the circularity test performed in this work. The improvement in surface texture has been analyzed through the scanning electron microscope images. As a result of the finishing capability of the currently designed in-situ tool, it is useful in a variety of industrial applications such as oil pipes, bearings, hydraulic cylinders, cylindrical molds, cylindrical barrels of injection molding machines, compressor bodies, valve bodies, etc.
{"title":"Development of a new in-situ rotating magnetorheological honing technique for fine finishing the inner cylindric surfaces","authors":"S. Paswan, Anant Kumar Singh","doi":"10.1080/10910344.2022.2129990","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129990","url":null,"abstract":"Abstract A new in-situ rotary magnetorheological honing (RMRH) approach has been developed in this study to fine-finish the machined inner surface of cylindric workpieces with increased productivity and dimensional accuracy. A single in-situ honing tool is used for performing both traditional as well as magnetorheological (MR) honing. The tool is fabricated based on the designed tool through magnetostatic analysis. In this work, the final MR finished surface is achieved up to 60 nm from the original machined surface roughness of 510 nm with the expense of 40 min of traditional honing and 60 min of MR finishing. Also, the great improvement in surface waviness is confirmed through the final surface waviness is achieved as 50 nm from the initial surface waviness of 1460 nm. The improvement in circularity is confirmed through the circularity test performed in this work. The improvement in surface texture has been analyzed through the scanning electron microscope images. As a result of the finishing capability of the currently designed in-situ tool, it is useful in a variety of industrial applications such as oil pipes, bearings, hydraulic cylinders, cylindrical molds, cylindrical barrels of injection molding machines, compressor bodies, valve bodies, etc.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"665 - 699"},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43447879","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129989
G. Toker, J. Schoop, H. Karaca
Abstract In this study, the effects of cryogenic and flood cooling on the surface integrity of Inconel 718 are investigated for face turning with four selected cutting speeds of 25, 50, 75 and 100 m/min. Surface integrity of machined samples was characterized in terms of surface morphology, sub-surface microstructure, microhardness, x-ray diffraction textures, and residual stresses. While the differences between cryogenic and flood cooling were relatively limited for the majority of surface integrity metrics, a substantially increased (+80% vs flood condition) nanolayer depth was observed at the highest cutting speed of 100 m/min with cryogenic cooling. Additionally, cryogenic cooling resulted in slightly improved surface roughness and slightly increased compressive residual stress, particularly at elevated cutting speeds. Nb-rich secondary phases were detected after machining for all conditions, however, cryogenic cooling and low cutting speed led to reduced mixing of these nanocrystalized phases in the recrystallized surface layer. Based on these observations a and qualitative model for surface generation and nanocrystallization under flood and cryogenic machining conditions was proposed. Overall, the effect of cryogenic cooling on nanolayer generation was most pronounced at elevated speeds, suggesting the potential for cryogenic cooling to allow for more aggressive, yet sustainable, processing strategies with improved surface integrity.
{"title":"Machining-induced surface integrity and nanocrystalline surface layers in cryogenic finishing turning of Inconel 718","authors":"G. Toker, J. Schoop, H. Karaca","doi":"10.1080/10910344.2022.2129989","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129989","url":null,"abstract":"Abstract In this study, the effects of cryogenic and flood cooling on the surface integrity of Inconel 718 are investigated for face turning with four selected cutting speeds of 25, 50, 75 and 100 m/min. Surface integrity of machined samples was characterized in terms of surface morphology, sub-surface microstructure, microhardness, x-ray diffraction textures, and residual stresses. While the differences between cryogenic and flood cooling were relatively limited for the majority of surface integrity metrics, a substantially increased (+80% vs flood condition) nanolayer depth was observed at the highest cutting speed of 100 m/min with cryogenic cooling. Additionally, cryogenic cooling resulted in slightly improved surface roughness and slightly increased compressive residual stress, particularly at elevated cutting speeds. Nb-rich secondary phases were detected after machining for all conditions, however, cryogenic cooling and low cutting speed led to reduced mixing of these nanocrystalized phases in the recrystallized surface layer. Based on these observations a and qualitative model for surface generation and nanocrystallization under flood and cryogenic machining conditions was proposed. Overall, the effect of cryogenic cooling on nanolayer generation was most pronounced at elevated speeds, suggesting the potential for cryogenic cooling to allow for more aggressive, yet sustainable, processing strategies with improved surface integrity.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"640 - 664"},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47118001","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129991
Sahil Sharma, Tarlochan Singh, A. Dvivedi
Abstract The requirement to fabricate the micro features in difficult-to-machine materials has increased the demand for new micro-machining processes. Over the years, various micro-machining processes have emerged, such as non-conventional, hybrid, and tandem micro-machining processes. Recently, among all of these processes, the tandem micro-machining processes have gained substantial attention. In these processes, two machining methods are arranged tandemly to mitigate the drawbacks of the primary one. This manuscript presents a comprehensive systematic review of the recent developments carried out in the novel tandem micro-machining processes. After conducting a literature review, the existing tandem micro-machining processes have been classified into four categories: Thermo plus Electrochemical, Thermo plus Mechanical, Thermo plus Thermo, and Hybrid plus Mechanical/Thermal. This work includes a detailed description of process conceptualization, process mechanisms, current development and capabilities of tandem micro-machining processes regarding work material and machined features. The manuscript’s originality illustrates how combining two processes could effectively produce intricate shapes in difficult-to-cut materials. Furthermore, the various steps involved in developing a tandem process from the idea formulation to the implementation stage have been discussed in the manuscript. The future opportunities in tandem micro-machining processes have also been identified and presented as research potential. While motivated by the systematic investigation, initial experimental results obtained from the in-house developed micro tandem machining processes such as W-EDM plus W-ECM and Laser plus W-ECM have also been included.
{"title":"Developments in tandem micro-machining processes to mitigate the machining issues at micron level: a systematic review, challenges and future opportunities","authors":"Sahil Sharma, Tarlochan Singh, A. Dvivedi","doi":"10.1080/10910344.2022.2129991","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129991","url":null,"abstract":"Abstract The requirement to fabricate the micro features in difficult-to-machine materials has increased the demand for new micro-machining processes. Over the years, various micro-machining processes have emerged, such as non-conventional, hybrid, and tandem micro-machining processes. Recently, among all of these processes, the tandem micro-machining processes have gained substantial attention. In these processes, two machining methods are arranged tandemly to mitigate the drawbacks of the primary one. This manuscript presents a comprehensive systematic review of the recent developments carried out in the novel tandem micro-machining processes. After conducting a literature review, the existing tandem micro-machining processes have been classified into four categories: Thermo plus Electrochemical, Thermo plus Mechanical, Thermo plus Thermo, and Hybrid plus Mechanical/Thermal. This work includes a detailed description of process conceptualization, process mechanisms, current development and capabilities of tandem micro-machining processes regarding work material and machined features. The manuscript’s originality illustrates how combining two processes could effectively produce intricate shapes in difficult-to-cut materials. Furthermore, the various steps involved in developing a tandem process from the idea formulation to the implementation stage have been discussed in the manuscript. The future opportunities in tandem micro-machining processes have also been identified and presented as research potential. While motivated by the systematic investigation, initial experimental results obtained from the in-house developed micro tandem machining processes such as W-EDM plus W-ECM and Laser plus W-ECM have also been included.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"515 - 570"},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42424111","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract Carbon fiber reinforced polymer (CFRP) is prone to surface damage such as delamination, uncut fibers and tear during the process of hole-making in aerospace field. Helical milling greatly improves the exit damage of CFRP holes, but the entrance damage will further deteriorate. To further diminish hole entrance damage and enhance hole machining quality, this paper proposed a longitudinal torsional ultrasonic assisted helical milling method to investigate the formation mechanism of hole entrance damage based on a cutting fracture mechanism with a fiber angle of 0° to 180°. The differences of hole entrance damage between longitudinal torsional ultrasonic helical milling (LTUHM) and traditional helical milling (THM) were analysed by a series of comparative experiments. The results showed that longitudinal torsional ultrasonic machining significantly reduced the damage of CFRP holes compared to THM. The delamination damage factor and uncut fibers factor of the hole entrance are reduced to 24.92% and 20.28%, respectively, and the fiber fracture surface is flatter under LTUHM. The study provides a production guide for efficient hole-making of CFRP.
{"title":"The hole entrance damage in longitudinal torsional ultrasonic helical milling of CFRP composites","authors":"Xue Wang, Feng Jiao, Shun Zhang, Yuanxiao Li, J. Tong, Zhibin Feng","doi":"10.1080/10910344.2022.2129988","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129988","url":null,"abstract":"Abstract Carbon fiber reinforced polymer (CFRP) is prone to surface damage such as delamination, uncut fibers and tear during the process of hole-making in aerospace field. Helical milling greatly improves the exit damage of CFRP holes, but the entrance damage will further deteriorate. To further diminish hole entrance damage and enhance hole machining quality, this paper proposed a longitudinal torsional ultrasonic assisted helical milling method to investigate the formation mechanism of hole entrance damage based on a cutting fracture mechanism with a fiber angle of 0° to 180°. The differences of hole entrance damage between longitudinal torsional ultrasonic helical milling (LTUHM) and traditional helical milling (THM) were analysed by a series of comparative experiments. The results showed that longitudinal torsional ultrasonic machining significantly reduced the damage of CFRP holes compared to THM. The delamination damage factor and uncut fibers factor of the hole entrance are reduced to 24.92% and 20.28%, respectively, and the fiber fracture surface is flatter under LTUHM. The study provides a production guide for efficient hole-making of CFRP.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"619 - 639"},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43914177","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2022-07-04DOI: 10.1080/10910344.2022.2129987
Gaopan Lei, D. Zhu, Mingzhu Ren, Dihua Zhu
Abstract The structure of the blades on a blisk is generally characterized by spatial distortion and spatial bending. Electrochemical trepanning (ECTr) is an effective roughing method in blisk manufacturing. To improve the structural characteristics and the allowance distribution uniformity manufactured by ECTr, a new feeding strategy, in which the relative motion of the cathode and the workpiece is due to simultaneous rotational feeding (RF) and shift feeding (SF), is proposed. The approach is called the rotational feeding combined with shift feeding (RF-SF) strategy. A parametric model and an optimized method for calculating the feeding trajectory (FT) under the RF-SF strategy are presented. To assess the effectiveness of the proposed method, the FTs for a twisted blade with variable cross section and a degree of bending were calculated and simulated for the RF and RF-SF strategies. Compared with the RF strategy, the uniformity of the allowance distribution under the RF-SF strategy was improved by 60.4% and 50.3% at the concave and convex parts, respectively. A blade was machined with RF-SF ECTr. The deviations between the experimental and simulated results were 7.1% and 8.1%, respectively, thereby verifying the effectiveness of the proposed method.
{"title":"Rotational feeding combined with shift feeding in the electrochemical trepanning of a blisk","authors":"Gaopan Lei, D. Zhu, Mingzhu Ren, Dihua Zhu","doi":"10.1080/10910344.2022.2129987","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129987","url":null,"abstract":"Abstract The structure of the blades on a blisk is generally characterized by spatial distortion and spatial bending. Electrochemical trepanning (ECTr) is an effective roughing method in blisk manufacturing. To improve the structural characteristics and the allowance distribution uniformity manufactured by ECTr, a new feeding strategy, in which the relative motion of the cathode and the workpiece is due to simultaneous rotational feeding (RF) and shift feeding (SF), is proposed. The approach is called the rotational feeding combined with shift feeding (RF-SF) strategy. A parametric model and an optimized method for calculating the feeding trajectory (FT) under the RF-SF strategy are presented. To assess the effectiveness of the proposed method, the FTs for a twisted blade with variable cross section and a degree of bending were calculated and simulated for the RF and RF-SF strategies. Compared with the RF strategy, the uniformity of the allowance distribution under the RF-SF strategy was improved by 60.4% and 50.3% at the concave and convex parts, respectively. A blade was machined with RF-SF ECTr. The deviations between the experimental and simulated results were 7.1% and 8.1%, respectively, thereby verifying the effectiveness of the proposed method.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"595 - 618"},"PeriodicalIF":2.7,"publicationDate":"2022-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47276520","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：