Abstract Based on the modified KM (Kock–Mecking) model, a cutting constitutive model of AA7050-T7451 considering anisotropy is established in this article. With the aid of high-speed cutting FEM simulation and experiment, the micro-influence mechanism of anisotropy on high-speed cutting hardening of AA7050-T7451 was studied from three aspects: micro-morphology, residual strain, and plastic deformation. By analyzing the macro-micro correlation mechanism of dislocation density, work hardening, and cutting temperature, a “Three-Stage” model of work hardening is put forward. The results show that the work-hardening behavior of high-speed cutting AA7050-T7451 shows obvious anisotropic characteristics. And the work hardening degree is less than 0° and 90° at the material forming angle of 45°. At the 45° forming angle, the material dislocation density is the highest, and the grains are most prone to the dislocation slip. The macroscopic properties show that the microhardness of the material is small. The “Three-stage” model reveals the micro-evolution mechanism of work-hardening behavior. It is found that the dislocation density dominates the work-hardening behavior in stages I and II, and cutting temperature dominates the work-hardening behavior in stage III. The microhardness of the material increases sharply at first and then tends to be flat.
{"title":"Dislocation density evolution and hardening mechanism of AA7050-T7451 surface layer based on anisotropy","authors":"Zhenda Wang, Yongzhi Pan, Hui Wang, Zewen Zhang, X. Fu, Xiuhua Men","doi":"10.1080/10910344.2023.2194965","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194965","url":null,"abstract":"Abstract Based on the modified KM (Kock–Mecking) model, a cutting constitutive model of AA7050-T7451 considering anisotropy is established in this article. With the aid of high-speed cutting FEM simulation and experiment, the micro-influence mechanism of anisotropy on high-speed cutting hardening of AA7050-T7451 was studied from three aspects: micro-morphology, residual strain, and plastic deformation. By analyzing the macro-micro correlation mechanism of dislocation density, work hardening, and cutting temperature, a “Three-Stage” model of work hardening is put forward. The results show that the work-hardening behavior of high-speed cutting AA7050-T7451 shows obvious anisotropic characteristics. And the work hardening degree is less than 0° and 90° at the material forming angle of 45°. At the 45° forming angle, the material dislocation density is the highest, and the grains are most prone to the dislocation slip. The macroscopic properties show that the microhardness of the material is small. The “Three-stage” model reveals the micro-evolution mechanism of work-hardening behavior. It is found that the dislocation density dominates the work-hardening behavior in stages I and II, and cutting temperature dominates the work-hardening behavior in stage III. The microhardness of the material increases sharply at first and then tends to be flat.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48854191","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 : 2023-01-02DOI: 10.1080/10910344.2023.2194959
Shiyu Wei, P. Zou, J. Duan, K. Ehmann
Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic vibration-assisted turning (3D-UVAT). The integrity of the obtained workpiece surfaces will be systematically explored in terms of surface roughness, the microstructure of the surface obtained by heat-assisted turning, surface hardness and wettability. A comparative assessment with other surface generation methods, i.e., common turning (CT), one-dimensional (UVAT) and two-dimensional elliptical ultrasonic vibration-assisted turning (EUAT) is also given. The results show that 3D-UVAT can reduce the depth of surface damage and enhance the hydrophobicity of the surface while reducing surface roughness.
{"title":"Surface integrity in 3D ultrasonic vibration-assisted turning driven by two actuators","authors":"Shiyu Wei, P. Zou, J. Duan, K. Ehmann","doi":"10.1080/10910344.2023.2194959","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194959","url":null,"abstract":"Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic vibration-assisted turning (3D-UVAT). The integrity of the obtained workpiece surfaces will be systematically explored in terms of surface roughness, the microstructure of the surface obtained by heat-assisted turning, surface hardness and wettability. A comparative assessment with other surface generation methods, i.e., common turning (CT), one-dimensional (UVAT) and two-dimensional elliptical ultrasonic vibration-assisted turning (EUAT) is also given. The results show that 3D-UVAT can reduce the depth of surface damage and enhance the hydrophobicity of the surface while reducing surface roughness.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48333609","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 : 2023-01-02DOI: 10.1080/10910344.2023.2194958
Hao Li, Tao Chen, Hongbo Li, Yiwen Zhang
Abstract Conventional surface grinding can be divided into up grinding and down grinding according to rotation direction of spindle. Nevertheless, the effects and differences of ultrasonic vibration on the two machining methods have been less reported. The influence of ultrasonic vibration amplitude on cutting force, surface roughness and surface topography were investigated in this paper by conducting tangential and radial ultrasonic vibration assisted down/up grinding comparison experiments on SiC. The results showed that the grinding force of down grinding was less than that of up grinding in conventional grinding, while the surface roughness was greater than that of up grinding. The grinding forces of both down grinding and up grinding were reduced to different ratios after applying different ultrasonic vibration, while the surface roughness increased. The grinding force of up grinding decreased and then increased with the increase of amplitude, while the grinding force of down grinding kept decreasing and the surface roughness decreased. The reasons for the differences in cutting forces and surface quality between the two grinding methods after the application of ultrasonic vibration are discussed. By observing the surface morphology, the percentage of ductile area on the machined surface decreases and then increases with the increase of amplitude.
{"title":"Influence of ultrasonic vibration on machining quality of down/up grinding in ultrasonic vibration assisted grinding of silicon carbide","authors":"Hao Li, Tao Chen, Hongbo Li, Yiwen Zhang","doi":"10.1080/10910344.2023.2194958","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194958","url":null,"abstract":"Abstract Conventional surface grinding can be divided into up grinding and down grinding according to rotation direction of spindle. Nevertheless, the effects and differences of ultrasonic vibration on the two machining methods have been less reported. The influence of ultrasonic vibration amplitude on cutting force, surface roughness and surface topography were investigated in this paper by conducting tangential and radial ultrasonic vibration assisted down/up grinding comparison experiments on SiC. The results showed that the grinding force of down grinding was less than that of up grinding in conventional grinding, while the surface roughness was greater than that of up grinding. The grinding forces of both down grinding and up grinding were reduced to different ratios after applying different ultrasonic vibration, while the surface roughness increased. The grinding force of up grinding decreased and then increased with the increase of amplitude, while the grinding force of down grinding kept decreasing and the surface roughness decreased. The reasons for the differences in cutting forces and surface quality between the two grinding methods after the application of ultrasonic vibration are discussed. By observing the surface morphology, the percentage of ductile area on the machined surface decreases and then increases with the increase of amplitude.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45495040","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 : 2023-01-02DOI: 10.1080/10910344.2023.2194964
A. Pratap, A. Gorodkova, K. Patra, Aleksandr A. Dyakonov
Abstract The objective of this work is to characterize the heat transfer and temperature generation into the workpiece during micro-slot grinding. A numerical model for predicting micro-grinding temperature is established based on the finite difference method (FDM). Workpiece volume is divided into small elementary sections and temperature in small sections near and away from the machining zone is calculated using thermo-physical model as well as validated by experimentally measured temperature using infrared technique. Temperature in micro-slot grinding increases during vertical insertion of the tool and becomes stable when the tool transverse in the feed direction. Simulation results show that transient heat transfer becomes dominant on increased feed rate values that result in an overall lowering of heat supply into the surface. Results also reveal that modification in the tool design has a significant impact on the reduction of workpiece temperature due to reduced contact length, reduced cutting forces, friction, and rubbing at the tool-workpiece interface. The proposed model is capable of solving transient problems in micro-slot grinding and is flexible to deal with different boundary conditions. This analysis will help in temperature prediction and establishing temperature reduction strategies that could potentially increase machining precision.
{"title":"Finite difference numerical modeling and experimental validation of workpiece surface temperature in micro-grinding","authors":"A. Pratap, A. Gorodkova, K. Patra, Aleksandr A. Dyakonov","doi":"10.1080/10910344.2023.2194964","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194964","url":null,"abstract":"Abstract The objective of this work is to characterize the heat transfer and temperature generation into the workpiece during micro-slot grinding. A numerical model for predicting micro-grinding temperature is established based on the finite difference method (FDM). Workpiece volume is divided into small elementary sections and temperature in small sections near and away from the machining zone is calculated using thermo-physical model as well as validated by experimentally measured temperature using infrared technique. Temperature in micro-slot grinding increases during vertical insertion of the tool and becomes stable when the tool transverse in the feed direction. Simulation results show that transient heat transfer becomes dominant on increased feed rate values that result in an overall lowering of heat supply into the surface. Results also reveal that modification in the tool design has a significant impact on the reduction of workpiece temperature due to reduced contact length, reduced cutting forces, friction, and rubbing at the tool-workpiece interface. The proposed model is capable of solving transient problems in micro-slot grinding and is flexible to deal with different boundary conditions. This analysis will help in temperature prediction and establishing temperature reduction strategies that could potentially increase machining precision.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49469574","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 : 2022-11-02DOI: 10.1080/10910344.2023.2180751
Ganesan G., Ganesh Malayath, R. Mote
Abstract Ultra-precision cutting (UPC) is an advanced machining process capable of fabricating components with a surface finish and dimensional accuracy in the nanometer range. The cutting tool edge should possess ultra-sharpness and controlled waviness to bring off a higher degree of finish and accuracy. It also should have high hardness, toughness, thermal resistance and chemical inertness. As the cutting-edge radius is in order of nm, the edge characterization is always arduous. Profound knowledge regarding the wear patterns of the UPC tools is indispensable as it will affect the machining quality to a great extent. Hence, to employ a cutting tool for UPC operations, one should know the different variants of UPC and their characteristics, different tool materials and their properties, geometries and how it affects machining accuracy, various edge preparation method and characterization techniques and their limitations, associated measurement errors, tool wear patterns and processes to control the wear. These diverse areas have to be brought under a single roof to systematically choose the material, geometry, and fabrication method for UPC tools. This article provides a comprehensive review of the research related to cutting tools of UPC to understand and evaluate the current trends in the development of UPC tools. Graphical abstract
{"title":"A review of cutting tools for ultra-precision machining","authors":"Ganesan G., Ganesh Malayath, R. Mote","doi":"10.1080/10910344.2023.2180751","DOIUrl":"https://doi.org/10.1080/10910344.2023.2180751","url":null,"abstract":"Abstract Ultra-precision cutting (UPC) is an advanced machining process capable of fabricating components with a surface finish and dimensional accuracy in the nanometer range. The cutting tool edge should possess ultra-sharpness and controlled waviness to bring off a higher degree of finish and accuracy. It also should have high hardness, toughness, thermal resistance and chemical inertness. As the cutting-edge radius is in order of nm, the edge characterization is always arduous. Profound knowledge regarding the wear patterns of the UPC tools is indispensable as it will affect the machining quality to a great extent. Hence, to employ a cutting tool for UPC operations, one should know the different variants of UPC and their characteristics, different tool materials and their properties, geometries and how it affects machining accuracy, various edge preparation method and characterization techniques and their limitations, associated measurement errors, tool wear patterns and processes to control the wear. These diverse areas have to be brought under a single roof to systematically choose the material, geometry, and fabrication method for UPC tools. This article provides a comprehensive review of the research related to cutting tools of UPC to understand and evaluate the current trends in the development of UPC tools. Graphical abstract","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43306533","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 : 2022-11-02DOI: 10.1080/10910344.2023.2181088
H. Tsai, W. Hsu, Ming You
Abstract Microbial fuel cells (MFCs), which generate low-pollution power through feeding organic trace minerals to bacteria, are crucial for applications involving energy recovery and environmental protection. In MFCs, electrodes critically influence the electrocatalytic process. In this study, an electrical-discharge-machining (EDM)-based surface treatment method for MFC electrodes was applied to a stainless-steel mesh (SSM), which was selected as an anode substrate. The experimental results indicated that EDM surface treatment formed a recast layer on the SSM anode surface. A few defects such as cracks and notches were observed after EDM surface treatment, which increased the surface and surface roughness of the SSM anode. To verify the effectiveness of the proposed EDM treatment, an Escherichia coli (HB101)-based single-chamber MFC system was fabricated, and the electrochemical activity of the EDM-treated anode was investigated through electrochemical analysis. The maximum power density of the MFCs equipped with the untreated SSM anode and the EDM-treated SSM anode under a pulse current of 1.5 A were 101.37 and 205.94 mW m−2, respectively. Thus, EDM surface treatment increased the power generated by the MFC by a factor of approximately 2. The proposed novel EDM surface treatment, therefore, has potential for development as a standard processing procedure for metal electrode substrates.
{"title":"Electrical discharge machining as a surface treatment process for improving the performance of microbial fuel cells","authors":"H. Tsai, W. Hsu, Ming You","doi":"10.1080/10910344.2023.2181088","DOIUrl":"https://doi.org/10.1080/10910344.2023.2181088","url":null,"abstract":"Abstract Microbial fuel cells (MFCs), which generate low-pollution power through feeding organic trace minerals to bacteria, are crucial for applications involving energy recovery and environmental protection. In MFCs, electrodes critically influence the electrocatalytic process. In this study, an electrical-discharge-machining (EDM)-based surface treatment method for MFC electrodes was applied to a stainless-steel mesh (SSM), which was selected as an anode substrate. The experimental results indicated that EDM surface treatment formed a recast layer on the SSM anode surface. A few defects such as cracks and notches were observed after EDM surface treatment, which increased the surface and surface roughness of the SSM anode. To verify the effectiveness of the proposed EDM treatment, an Escherichia coli (HB101)-based single-chamber MFC system was fabricated, and the electrochemical activity of the EDM-treated anode was investigated through electrochemical analysis. The maximum power density of the MFCs equipped with the untreated SSM anode and the EDM-treated SSM anode under a pulse current of 1.5 A were 101.37 and 205.94 mW m−2, respectively. Thus, EDM surface treatment increased the power generated by the MFC by a factor of approximately 2. The proposed novel EDM surface treatment, therefore, has potential for development as a standard processing procedure for metal electrode substrates.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45601783","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 : 2022-11-02DOI: 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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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}
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