Pub Date : 2022-05-04DOI: 10.1080/10910344.2022.2129984
A. L. Pissolatti, A. Magri, A. Antonialli, A. Diniz
Abstract Regarding milling of dies and molds, there are several geometric requirements, and it is absolutely not trivial to machine complex either concave or convex surfaces. Since the contact between tool and workpiece changes all the time, making the components of the milling forces also to change, it is fundamental to find the correct milling strategies which cause the smallest variation of cutting forces (amplitude and sense) in order to obtain the best possible workpiece surface quality. In this work, four different machining strategies for finish milling of D6 tool steel were studied. They were compared in terms of surface roughness, cutting force, and tool wear at the end of tool life. Results show that lower surface roughness was obtained using descending down milling and ascending up milling because the sense of the cutting force components, specially the one that is normal to the machined surface on the most critic region of the workpiece, pulled the workpiece against the tool and the tool against the workpiece. On the other hand, descending up milling and ascending down milling did not present good results because the sense of the force components was responsible for excessive tool bending moving the tool and workpiece apart.
{"title":"Comparing surface roughness and tool wear when milling convex surface of hardened steel using different milling strategies","authors":"A. L. Pissolatti, A. Magri, A. Antonialli, A. Diniz","doi":"10.1080/10910344.2022.2129984","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129984","url":null,"abstract":"Abstract Regarding milling of dies and molds, there are several geometric requirements, and it is absolutely not trivial to machine complex either concave or convex surfaces. Since the contact between tool and workpiece changes all the time, making the components of the milling forces also to change, it is fundamental to find the correct milling strategies which cause the smallest variation of cutting forces (amplitude and sense) in order to obtain the best possible workpiece surface quality. In this work, four different machining strategies for finish milling of D6 tool steel were studied. They were compared in terms of surface roughness, cutting force, and tool wear at the end of tool life. Results show that lower surface roughness was obtained using descending down milling and ascending up milling because the sense of the cutting force components, specially the one that is normal to the machined surface on the most critic region of the workpiece, pulled the workpiece against the tool and the tool against the workpiece. On the other hand, descending up milling and ascending down milling did not present good results because the sense of the force components was responsible for excessive tool bending moving the tool and workpiece apart.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44780956","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 : 2022-05-04DOI: 10.1080/10910344.2022.2129983
Van Tao Le
Abstract In the literature, investigations on the electrical discharge machining (EDM) process with Tungsten carbide powder mixed into dielectric fluid, also called PMEDM, are still limited. In this study, machining performances of PMEDM, including material removal rate (MRR) of AISI H13 steel and tool wear rate (TWR), were investigated in the semi-finishing process. Thereafter, recast layer properties of AISI H13 steel, including composition and content of chemical elements, recast layer thickness (RLT), and acreage percentage of micro-cracks on surfaces (APCS), were evaluated and discussed. Quantitative methods of MRR, TWR, RLT, APCS, and the composition and content of chemical elements on machined surfaces have been proposed. The results revealed that machining performances and recast layer properties were influenced by peak current (Ip), pulse on time (Ton), and powder concentration (Cp). MRR and TWR have been changed in an uptrend when Ip, Ton, and Cp increased. The chemical composition of machined surfaces was modified. APCS and RLT formed by PMEDM are notably decreased as compared with EDM, with a reduction of 41.093% and 48.982%, respectively. In addition, the changing trend of machining performances and recast layer properties were also explored.
{"title":"The evaluation of machining performances and recast layer properties of AISI H13 steel processed by tungsten carbide powder mixed EDM process in the semi-finishing process","authors":"Van Tao Le","doi":"10.1080/10910344.2022.2129983","DOIUrl":"https://doi.org/10.1080/10910344.2022.2129983","url":null,"abstract":"Abstract In the literature, investigations on the electrical discharge machining (EDM) process with Tungsten carbide powder mixed into dielectric fluid, also called PMEDM, are still limited. In this study, machining performances of PMEDM, including material removal rate (MRR) of AISI H13 steel and tool wear rate (TWR), were investigated in the semi-finishing process. Thereafter, recast layer properties of AISI H13 steel, including composition and content of chemical elements, recast layer thickness (RLT), and acreage percentage of micro-cracks on surfaces (APCS), were evaluated and discussed. Quantitative methods of MRR, TWR, RLT, APCS, and the composition and content of chemical elements on machined surfaces have been proposed. The results revealed that machining performances and recast layer properties were influenced by peak current (Ip), pulse on time (Ton), and powder concentration (Cp). MRR and TWR have been changed in an uptrend when Ip, Ton, and Cp increased. The chemical composition of machined surfaces was modified. APCS and RLT formed by PMEDM are notably decreased as compared with EDM, with a reduction of 41.093% and 48.982%, respectively. In addition, the changing trend of machining performances and recast layer properties were also explored.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47915006","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044857
Tarlochan Singh, J. Arab, P. Dixit
Abstract Continuous demands to develop advanced radio-frequency transmission at higher frequencies have initiated glass-based materials as a substrate in radio-frequency micro-electro-mechanical-systems (MEMS) applications. Due to its superior electrical insulation characteristics, glass has lower substrate losses than silicon when an electrical signal is transmitted at higher frequencies. The optical transparent nature of glass substrate makes it an attractive choice for microfluidics and Bio-MEMS applications. Despite having superior properties, glass usage has remained limited mainly due to the lack of suitable micromachining processes. Due to its hard and brittle nature, creating microfeatures by conventional methods has been a challenge. To date, laser ablation and plasma etching have been employed to create micro-size through-holes in glass substrate; however, both have severe process limitations. Electrochemical discharge drilling (ECDD) is an emerging method that possesses similar capabilities as existing technologies at a low cost. Therefore, this manuscript is presented to describe the ECDD process's potential and their hybrid methods in the direction of fabricating micro-holes for MEMS applications. This manuscript includes the fundamental aspects of the ECDD process and a detailed description of components used to develop its various configurations. ECDD-based hybrid methods have also been presented along with their mechanisms and capabilities. The existing challenges and the possible research potentials have been derived based on previously reported capabilities to establish the correlation between the ECDD process and MEMS devices.
{"title":"A review on microholes formation in glass-based substrates by electrochemical discharge drilling for MEMS applications","authors":"Tarlochan Singh, J. Arab, P. Dixit","doi":"10.1080/10910344.2022.2044857","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044857","url":null,"abstract":"Abstract Continuous demands to develop advanced radio-frequency transmission at higher frequencies have initiated glass-based materials as a substrate in radio-frequency micro-electro-mechanical-systems (MEMS) applications. Due to its superior electrical insulation characteristics, glass has lower substrate losses than silicon when an electrical signal is transmitted at higher frequencies. The optical transparent nature of glass substrate makes it an attractive choice for microfluidics and Bio-MEMS applications. Despite having superior properties, glass usage has remained limited mainly due to the lack of suitable micromachining processes. Due to its hard and brittle nature, creating microfeatures by conventional methods has been a challenge. To date, laser ablation and plasma etching have been employed to create micro-size through-holes in glass substrate; however, both have severe process limitations. Electrochemical discharge drilling (ECDD) is an emerging method that possesses similar capabilities as existing technologies at a low cost. Therefore, this manuscript is presented to describe the ECDD process's potential and their hybrid methods in the direction of fabricating micro-holes for MEMS applications. This manuscript includes the fundamental aspects of the ECDD process and a detailed description of components used to develop its various configurations. ECDD-based hybrid methods have also been presented along with their mechanisms and capabilities. The existing challenges and the possible research potentials have been derived based on previously reported capabilities to establish the correlation between the ECDD process and MEMS devices.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44359640","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044852
V. M, Ramanujam R, Gururaj Parande, M. Gupta
Abstract Advanced machining has become one of the inevitable processes for the fabrication of miniature industrial components that demands high dimensional accuracy. Magnesium (Mg) and its composites have widespread applications in the areas of aerospace, medical, and automobile sectors. The objective of this work is to analyze the machinability of Mg—rare earth (RE) alloy (Mg3Al2.5La)-based nanocomposites using wire electrical discharge turning (WEDT), a variant of EDM process. Y2O3 (0.6 and 1.9%) reinforced magnesium composites are prepared through disintegrated melt deposition technique. SEM and XRD analyses confirmed the intermetallic phase formation, such as Al11La3, and Al2La. Machining experiments are conducted with input parameters: discharge ON time, wire feed and spindle rotational speed each varied at three levels to study surface roughness (Ra) and volume of material removed (MRR). Results showed that Ra of the machined samples increases and MRR decreases, with the increase in % reinforcement and discharge ON time. The lower Ra value of 2.985 µm and higher MRR of 34.85 mm3/min are observed for the Mg3Al2.5La sample. This result is attributed to the absence of particle pullout and increased thermal conductivity of magnesium alloy during machining. Prediction analysis based on mean values is carried out to confirm the accuracy of the experimental results at optimal parametric levels.
{"title":"Machining of Y2O3 reinforced magnesium rare earth alloys using wire electrical discharge turning process","authors":"V. M, Ramanujam R, Gururaj Parande, M. Gupta","doi":"10.1080/10910344.2022.2044852","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044852","url":null,"abstract":"Abstract Advanced machining has become one of the inevitable processes for the fabrication of miniature industrial components that demands high dimensional accuracy. Magnesium (Mg) and its composites have widespread applications in the areas of aerospace, medical, and automobile sectors. The objective of this work is to analyze the machinability of Mg—rare earth (RE) alloy (Mg3Al2.5La)-based nanocomposites using wire electrical discharge turning (WEDT), a variant of EDM process. Y2O3 (0.6 and 1.9%) reinforced magnesium composites are prepared through disintegrated melt deposition technique. SEM and XRD analyses confirmed the intermetallic phase formation, such as Al11La3, and Al2La. Machining experiments are conducted with input parameters: discharge ON time, wire feed and spindle rotational speed each varied at three levels to study surface roughness (Ra) and volume of material removed (MRR). Results showed that Ra of the machined samples increases and MRR decreases, with the increase in % reinforcement and discharge ON time. The lower Ra value of 2.985 µm and higher MRR of 34.85 mm3/min are observed for the Mg3Al2.5La sample. This result is attributed to the absence of particle pullout and increased thermal conductivity of magnesium alloy during machining. Prediction analysis based on mean values is carried out to confirm the accuracy of the experimental results at optimal parametric levels.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44249634","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044853
Ashwani Sharma, M. Z. Khan Yusufzai, M. Vashista
Abstract Difficult-to-cut material, i.e., AISI D2 tool steel, has been widely adopted in metalworking industries to manufacture dies for piercing, blanking, drawing and thread rolling due to its excellent wear resistance and non-deforming properties. This article attempts an experimental study to determine the effect of cryogenic coolant (liquid nitrogen) on the grindability of AISI D2 tool steel as work material and its results are compared with the conventional dry and wet grinding methods. The effects of the cryogenic coolant on force components (i.e., tangential force, Ft and normal force, Fn ), specific grinding energy (u), force ratio, surface roughness parameters (Ra and Rz ) and microstructure were observed. The comparison results indicate a significant reduction in grindability indices such as 64% and 44% in Ft , 54% and 34% in Fn , 46% and 30% in Ra and 40% and 34% in Rz , respectively under cryogenic grinding at higher downfeed as followed to dry and wet grinding. The grinding performance in Ft , Fn , u and Ra was also improved with an increased delivery pressure of the liquid nitrogen (LN2). From the results, it is concluded that cryogenic coolant offers an influential method to improve grinding performance and surface integrity of AISI D2 tool steel.
{"title":"A comparative analysis of grinding of AISI D2 tool steel under different environments","authors":"Ashwani Sharma, M. Z. Khan Yusufzai, M. Vashista","doi":"10.1080/10910344.2022.2044853","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044853","url":null,"abstract":"Abstract Difficult-to-cut material, i.e., AISI D2 tool steel, has been widely adopted in metalworking industries to manufacture dies for piercing, blanking, drawing and thread rolling due to its excellent wear resistance and non-deforming properties. This article attempts an experimental study to determine the effect of cryogenic coolant (liquid nitrogen) on the grindability of AISI D2 tool steel as work material and its results are compared with the conventional dry and wet grinding methods. The effects of the cryogenic coolant on force components (i.e., tangential force, Ft and normal force, Fn ), specific grinding energy (u), force ratio, surface roughness parameters (Ra and Rz ) and microstructure were observed. The comparison results indicate a significant reduction in grindability indices such as 64% and 44% in Ft , 54% and 34% in Fn , 46% and 30% in Ra and 40% and 34% in Rz , respectively under cryogenic grinding at higher downfeed as followed to dry and wet grinding. The grinding performance in Ft , Fn , u and Ra was also improved with an increased delivery pressure of the liquid nitrogen (LN2). From the results, it is concluded that cryogenic coolant offers an influential method to improve grinding performance and surface integrity of AISI D2 tool steel.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43784485","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044854
Cheng Fan, Kunshan Xu, Lei Zhang, Qiang Yuan, Qian Wang, Kejun Wang, Lining Sun
Abstract An integrated polishing and in-situ measurement machine tool with seven-axis and five-linkage is developed for manufacturing and measuring the complex curved surface such as blisk. Firstly, this paper introduces the structure and configuration of the machine tool. Then, the kinematic analyses of the polishing side and measuring side of the machine tool are carried out respectively and the inverse kinematic solutions of them are derived. The motion of each axis can be calculated based on the tool location of the complex curved surface through the inverse kinematic solution. Aiming at the in-situ measurement of parts with complex curved surfaces, the forward kinematic solution, the processing of measured data of blade surface and the calculation algorithm of the machining allowance are developed in the paper. Finally, the above algorithms are verified by polishing the experimental stainless-steel sample.
{"title":"Kinematic planning and in-situ measurement of seven-axis five-linkage grinding and polishing machine tool for complex curved surface","authors":"Cheng Fan, Kunshan Xu, Lei Zhang, Qiang Yuan, Qian Wang, Kejun Wang, Lining Sun","doi":"10.1080/10910344.2022.2044854","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044854","url":null,"abstract":"Abstract An integrated polishing and in-situ measurement machine tool with seven-axis and five-linkage is developed for manufacturing and measuring the complex curved surface such as blisk. Firstly, this paper introduces the structure and configuration of the machine tool. Then, the kinematic analyses of the polishing side and measuring side of the machine tool are carried out respectively and the inverse kinematic solutions of them are derived. The motion of each axis can be calculated based on the tool location of the complex curved surface through the inverse kinematic solution. Aiming at the in-situ measurement of parts with complex curved surfaces, the forward kinematic solution, the processing of measured data of blade surface and the calculation algorithm of the machining allowance are developed in the paper. Finally, the above algorithms are verified by polishing the experimental stainless-steel sample.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44070079","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044856
P. Abhilash, D. Chakradhar
Abstract This study aims to develop a pulse classification algorithm to understand wire electric discharge machining (wire EDM) process stability and performance based on the discharge pulse characteristics. Also, a process data driven failure prediction system is proposed. The wire EDM monitoring system includes high sampling rate differential probes and current probes. The features extracted through pulse train analysis were spark discharge energy, ignition delay time, spark frequency and proportion of various discharges. A pulse discrimination algorithm was proposed, which classifies the discharges into open circuit sparks, arc discharges, short circuit sparks and normal sparks. It was observed that higher proportions of short circuit pulses resulted in inferior part quality. The differences in the pulse cycle during stable and unstable machining were studied based on the extracted features. It was found that the discharge frequency and the proportion of arc and short circuit pulses were extremely high before the wire breakages. An artificial neural network (ANN) model was developed to predict the process responses, like cutting speed and surface roughness, from the process data. Also, an intelligent algorithm was developed based on the extracted in-process data to predict the unstable conditions, leading to machining failures. The accuracy of the algorithm was confirmed to be very high by conducting confirmation tests.
{"title":"Performance monitoring and failure prediction system for wire electric discharge machining process through multiple sensor signals","authors":"P. Abhilash, D. Chakradhar","doi":"10.1080/10910344.2022.2044856","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044856","url":null,"abstract":"Abstract This study aims to develop a pulse classification algorithm to understand wire electric discharge machining (wire EDM) process stability and performance based on the discharge pulse characteristics. Also, a process data driven failure prediction system is proposed. The wire EDM monitoring system includes high sampling rate differential probes and current probes. The features extracted through pulse train analysis were spark discharge energy, ignition delay time, spark frequency and proportion of various discharges. A pulse discrimination algorithm was proposed, which classifies the discharges into open circuit sparks, arc discharges, short circuit sparks and normal sparks. It was observed that higher proportions of short circuit pulses resulted in inferior part quality. The differences in the pulse cycle during stable and unstable machining were studied based on the extracted features. It was found that the discharge frequency and the proportion of arc and short circuit pulses were extremely high before the wire breakages. An artificial neural network (ANN) model was developed to predict the process responses, like cutting speed and surface roughness, from the process data. Also, an intelligent algorithm was developed based on the extracted in-process data to predict the unstable conditions, leading to machining failures. The accuracy of the algorithm was confirmed to be very high by conducting confirmation tests.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46110530","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 : 2022-03-04DOI: 10.1080/10910344.2022.2044855
Ü. Şimşek, C. Çoğun, Ziya Esen
Abstract The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.
{"title":"Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)","authors":"Ü. Şimşek, C. Çoğun, Ziya Esen","doi":"10.1080/10910344.2022.2044855","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044855","url":null,"abstract":"Abstract The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42654031","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 The polycrystalline cubic boron nitride (PCBN) insert has been widely used in machining high chromium white cast iron (HCCI), which has the high hardness and abrasiveness. The aim of this article is to reveal that micro-mechanical properties play an essential role in assessing the machinability of high chromium cast iron. Grid nanoindentation is applied to measure the micro-hardness distribution. Based on grid nanoindentation results, the micro-hardness distribution is proposed to study the machinability. After the machining test of HCCI by the PCBN insert, the cutting force, tool wear, surface roughness, and chip formation showed that the micro-hardness distribution of materials has the better results than macro-hardness in machinability evaluation, and abrasive wear occurred on the rake and flank face of the cutting tool. The abrasiveness index that is related with the micro-hardness distribution and the abrasive wear effect in machining, for the most of high abrasion materials, has the possible to evaluate the dynamic cutting process and tool life in dry machining by using the PCBN insert. The micro-hardness distribution imported into the machinability model may propose a new way to improve the data exchange capability in the modern manufacturing process.
{"title":"Machinability study on dry machining of white cast iron by polycrystalline cubic boron nitride inserts","authors":"Xin Guo, Ling Chen, Wu Zhao, Hao Wan, Huiting Wen, Jinming Zhou","doi":"10.1080/10910344.2022.2044851","DOIUrl":"https://doi.org/10.1080/10910344.2022.2044851","url":null,"abstract":"Abstract The polycrystalline cubic boron nitride (PCBN) insert has been widely used in machining high chromium white cast iron (HCCI), which has the high hardness and abrasiveness. The aim of this article is to reveal that micro-mechanical properties play an essential role in assessing the machinability of high chromium cast iron. Grid nanoindentation is applied to measure the micro-hardness distribution. Based on grid nanoindentation results, the micro-hardness distribution is proposed to study the machinability. After the machining test of HCCI by the PCBN insert, the cutting force, tool wear, surface roughness, and chip formation showed that the micro-hardness distribution of materials has the better results than macro-hardness in machinability evaluation, and abrasive wear occurred on the rake and flank face of the cutting tool. The abrasiveness index that is related with the micro-hardness distribution and the abrasive wear effect in machining, for the most of high abrasion materials, has the possible to evaluate the dynamic cutting process and tool life in dry machining by using the PCBN insert. The micro-hardness distribution imported into the machinability model may propose a new way to improve the data exchange capability in the modern manufacturing process.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2022-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47305942","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 : 2021-12-23DOI: 10.1080/10910344.2021.1971707
Q. Niu, L. Jing, Z. Yu, C. P. Li, X. Qiu, T. Ko
Abstract Silicon carbide particulate-reinforced aluminum (SiCp/Al) composites is one of the typical difficult-to-cut materials, which are not suitable well for traditional machining any more. In order to explore new processing technology and verify its feasibility, this paper discussed the effects of cryogenic assisted milling with liquid nitrogen (LN2) coolant on the machinability of SiCp/Al composites. The effects of cryogenic milling were also compared with that of conventional dry milling. The results showed that cryogenic milling of 20% SiCp/Al composites would increase the surface hardness of the material, causing 15% higher amount of cutting force in cryogenic milling as compared to dry milling. In addition, there were serious tool feed marks on the machined surface under cryogenic condition because of the secondary cutting mechanism, which resulted in high surface roughness and poor surface quality. Overall, 46.73% higher roughness Ra and 31.53% roughness Rz were seen for cryogenic milling in comparison with dry milling technique respectively. The dish angle of milling tool and processing environment plays important roles in machined surface. Chip brittleness increased and short arc chips were formed in cryogenic milling. It was suggested that milling SiCp/Al composites under cryogenic condition had negative effects on the machinability of the material.
{"title":"Experimental study on cryogenic milling performance of SiCp/Al composites with liquid nitrogen","authors":"Q. Niu, L. Jing, Z. Yu, C. P. Li, X. Qiu, T. Ko","doi":"10.1080/10910344.2021.1971707","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971707","url":null,"abstract":"Abstract Silicon carbide particulate-reinforced aluminum (SiCp/Al) composites is one of the typical difficult-to-cut materials, which are not suitable well for traditional machining any more. In order to explore new processing technology and verify its feasibility, this paper discussed the effects of cryogenic assisted milling with liquid nitrogen (LN2) coolant on the machinability of SiCp/Al composites. The effects of cryogenic milling were also compared with that of conventional dry milling. The results showed that cryogenic milling of 20% SiCp/Al composites would increase the surface hardness of the material, causing 15% higher amount of cutting force in cryogenic milling as compared to dry milling. In addition, there were serious tool feed marks on the machined surface under cryogenic condition because of the secondary cutting mechanism, which resulted in high surface roughness and poor surface quality. Overall, 46.73% higher roughness Ra and 31.53% roughness Rz were seen for cryogenic milling in comparison with dry milling technique respectively. The dish angle of milling tool and processing environment plays important roles in machined surface. Chip brittleness increased and short arc chips were formed in cryogenic milling. It was suggested that milling SiCp/Al composites under cryogenic condition had negative effects on the machinability of the material.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49081336","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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