Pub Date : 2021-12-21DOI: 10.1080/10910344.2021.1998829
A. Hassouna, S. Mzali, F. Zemzemi, S. Mezlini
Abstract Short glass fiber composites, particularly sheet molding compound (SMC) materials, are becoming increasingly important alternative in various contemporary aerospace, automotive, and electronic applications. For these manufacturing industries, the quality of the machined SMC composite is still a challenging target. The article proposes a new tool design with an offset between teeth to minimize friction, limit damage and promote chip removal when drilling composite materials. The effects of the tool’s geometric parameters, especially the rake, the inclination and the complementary side cutting edge angles on the material removal process, as well as the cutting and thrust forces, are investigated. A 3D finite element model of a representative multi-tooth tool is developed using the ABAQUSExplicit code. The results show that fine-tuning the geometric parameters of the tool reduces the induced machining damage and enhances the chip removal and the flow evolution. The rake angle has a significant influence on the cutting and thrust forces. However, both forces are insensitive to the inclination angle. The complementary side cutting edge angle influences only the thrust force. The presented outcomes not only give insights into the cutting process, but also improve the SMC machinability.
{"title":"Effect of geometrical parameters and tool pattern of multi-tooth sawing on cutting of sheet molding compound composite: FE study","authors":"A. Hassouna, S. Mzali, F. Zemzemi, S. Mezlini","doi":"10.1080/10910344.2021.1998829","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998829","url":null,"abstract":"Abstract Short glass fiber composites, particularly sheet molding compound (SMC) materials, are becoming increasingly important alternative in various contemporary aerospace, automotive, and electronic applications. For these manufacturing industries, the quality of the machined SMC composite is still a challenging target. The article proposes a new tool design with an offset between teeth to minimize friction, limit damage and promote chip removal when drilling composite materials. The effects of the tool’s geometric parameters, especially the rake, the inclination and the complementary side cutting edge angles on the material removal process, as well as the cutting and thrust forces, are investigated. A 3D finite element model of a representative multi-tooth tool is developed using the ABAQUSExplicit code. The results show that fine-tuning the geometric parameters of the tool reduces the induced machining damage and enhances the chip removal and the flow evolution. The rake angle has a significant influence on the cutting and thrust forces. However, both forces are insensitive to the inclination angle. The complementary side cutting edge angle influences only the thrust force. The presented outcomes not only give insights into the cutting process, but also improve the SMC machinability.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43040204","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 : 2021-12-21DOI: 10.1080/10910344.2021.1998107
E. Tascioglu, Y. Kaynak, S. Sharif, Fatih Pitir, M. A. Suhaimi
Abstract Parameters used in laser powder bed fusion (LPBF) process are key factors that influence the surface integrity and thus mechanical properties of Inconel 718 components fabricated by additive manufacturing (AM) technique. For this reason, various parameters with different settings through trial and error approach have used by AM community to fabricate Inconel 718 components. These AM fabricated components generally required post treatment or processing including finish machining, to enhance their surface properties. This study presents a systematic investigation on the effect of volumetric energy density, and various LPBF processing parameters including laser power, layer thickness, and scanning speed on the as-printed specimens and the surface integrity aspects, namely surface quality, porosity, and microhardness. Furthermore, using machining operations specifically finish milling on these specimens under constant machining parameters, the effect of as-printed conditions on the machinability responses including burr formation, cutting forces are evaluated accordingly. Moreover, the interrelationship between LPBF processing parameters-machining-surface and subsurface aspects are also examined. This study reveals that LPBF additive manufacturing parameters have remarkable influence on the printed Inconel 718 specimens. Results also showed that parameters including laser power, scanning speed and layer thickness also have an effect on both the machinability and final surface and subsurface properties of the AM fabricated Inconel 718 specimens. It should be also noted that there is a notable relationship between volumetric energy density and the machinability of the AM printed Inconel 718.
{"title":"Machining-induced surface integrity of Inconel 718 alloy fabricated by powder bed fusion additive manufacturing under various laser processing parameters","authors":"E. Tascioglu, Y. Kaynak, S. Sharif, Fatih Pitir, M. A. Suhaimi","doi":"10.1080/10910344.2021.1998107","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998107","url":null,"abstract":"Abstract Parameters used in laser powder bed fusion (LPBF) process are key factors that influence the surface integrity and thus mechanical properties of Inconel 718 components fabricated by additive manufacturing (AM) technique. For this reason, various parameters with different settings through trial and error approach have used by AM community to fabricate Inconel 718 components. These AM fabricated components generally required post treatment or processing including finish machining, to enhance their surface properties. This study presents a systematic investigation on the effect of volumetric energy density, and various LPBF processing parameters including laser power, layer thickness, and scanning speed on the as-printed specimens and the surface integrity aspects, namely surface quality, porosity, and microhardness. Furthermore, using machining operations specifically finish milling on these specimens under constant machining parameters, the effect of as-printed conditions on the machinability responses including burr formation, cutting forces are evaluated accordingly. Moreover, the interrelationship between LPBF processing parameters-machining-surface and subsurface aspects are also examined. This study reveals that LPBF additive manufacturing parameters have remarkable influence on the printed Inconel 718 specimens. Results also showed that parameters including laser power, scanning speed and layer thickness also have an effect on both the machinability and final surface and subsurface properties of the AM fabricated Inconel 718 specimens. It should be also noted that there is a notable relationship between volumetric energy density and the machinability of the AM printed Inconel 718.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49034215","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 : 2021-12-21DOI: 10.1080/10910344.2021.1998828
Wenbo Bie, Bo Zhao, Xiaobo Wang, Yi Wang, Baoqi Chang
Abstract In ultrasonic vibration-assisted drilling (UVAD), the processing stability is strongly influenced by the ultrasonic vibration system's vibrational characteristics. The effect of tool parameters on UVAD's vibrational characteristic was experimentally studied and theoretically analyzed in this paper. Firstly, a measurement experiment was designed to assess the above effect in three various tools under different loads. The relationship between the ultrasonic power and amplitude was used to indirectly monitor the ultrasonic amplitude variation, which was corroborated by the UVAD test results. The ultrasonic amplitude and power were mainly controlled by the stiffness coefficient, while the damping coefficient effect could be ignored. Furthermore, the tool vibration frequency exhibited an increasing trend with the load value. Finally, the effects of the stiffness coefficient and damping coefficient on the vibrational characteristics were theoretically substantiated. The results of this study are considered instrumental in selecting tool and process parameters in ultrasonic machining.
{"title":"Experimental study on the effect of tool parameters on the vibrational characteristic of ultrasonic vibration-assisted drilling system","authors":"Wenbo Bie, Bo Zhao, Xiaobo Wang, Yi Wang, Baoqi Chang","doi":"10.1080/10910344.2021.1998828","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998828","url":null,"abstract":"Abstract In ultrasonic vibration-assisted drilling (UVAD), the processing stability is strongly influenced by the ultrasonic vibration system's vibrational characteristics. The effect of tool parameters on UVAD's vibrational characteristic was experimentally studied and theoretically analyzed in this paper. Firstly, a measurement experiment was designed to assess the above effect in three various tools under different loads. The relationship between the ultrasonic power and amplitude was used to indirectly monitor the ultrasonic amplitude variation, which was corroborated by the UVAD test results. The ultrasonic amplitude and power were mainly controlled by the stiffness coefficient, while the damping coefficient effect could be ignored. Furthermore, the tool vibration frequency exhibited an increasing trend with the load value. Finally, the effects of the stiffness coefficient and damping coefficient on the vibrational characteristics were theoretically substantiated. The results of this study are considered instrumental in selecting tool and process parameters in ultrasonic machining.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-12-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46368322","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 : 2021-12-02DOI: 10.1080/10910344.2021.1998830
I. Prasanth, D. Ravishankar, M. Manzoor Hussain, Chandra Mouli Badiganti
Abstract The anisotropic nature of polymer composites presents many challenges for manufacturers to adopt appropriate machining processes. In the present investigation, end milling experiments were conducted on glass fiber reinforced polymer laminates with five varieties of customized cutting tools with different angles of rake and clearance. The performance of the tools was evaluated in terms of their machining force, surface roughness and delamination factor at spindle speeds in the range of 690–2500 rpm. From the observations, relatively high rake and angled clearance tools performed better than the rest of the tools under consideration in terms of delamination and machined surface finishing. The milling operations performed at a spindle speed of 1950 rpm produced better surface quality. Observations from SEM graphs, exposed surface defects due to milling, generated at lower spindle speeds of 690 rpm and at higher spindle speeds of 2500 rpm with the tool signature of low angle rake and angled clearance tools out of all five tools considered for the experiments.
{"title":"Influence of milling process parameters and significance of tools to improve the surface quality of GFRP composites","authors":"I. Prasanth, D. Ravishankar, M. Manzoor Hussain, Chandra Mouli Badiganti","doi":"10.1080/10910344.2021.1998830","DOIUrl":"https://doi.org/10.1080/10910344.2021.1998830","url":null,"abstract":"Abstract The anisotropic nature of polymer composites presents many challenges for manufacturers to adopt appropriate machining processes. In the present investigation, end milling experiments were conducted on glass fiber reinforced polymer laminates with five varieties of customized cutting tools with different angles of rake and clearance. The performance of the tools was evaluated in terms of their machining force, surface roughness and delamination factor at spindle speeds in the range of 690–2500 rpm. From the observations, relatively high rake and angled clearance tools performed better than the rest of the tools under consideration in terms of delamination and machined surface finishing. The milling operations performed at a spindle speed of 1950 rpm produced better surface quality. Observations from SEM graphs, exposed surface defects due to milling, generated at lower spindle speeds of 690 rpm and at higher spindle speeds of 2500 rpm with the tool signature of low angle rake and angled clearance tools out of all five tools considered for the experiments.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42368532","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 : 2021-11-08DOI: 10.1080/10910344.2021.1971713
K. Mishra, B. Sarkar, B. Bhattacharyya
Abstract Fabrication of high aspect ratio (HAR) complex micro features on high strength temperature resistant (HSTR) alloys is challenging by any conventional or non-conventional machining methods. In this study blind, HAR and complex micro features have been fabricated by micro electrochemical milling (MEM) on HSTR Cobalt alloy (Haynes-188) introducing a new strategic approach with novel flushing technique which could get rid of the need of pulsed DC power supply. Multiphysics simulation of the rotating micro-tool at different rpm and its impact on effective sludge removal has been analyzed and verified experimentally. In this study, most influencing parameters of MEM like voltage, feed rate, rpm of tool and milling layer depth have been selected to investigate their effects on the machining responses like width overcut, machined depth and surface roughness on Haynes-188 alloy. Comparison has also been made with constant and pulsed DC power source to know the influence of these process parameters on the MEM responses. Finally, several linear and non-linear blind, HAR (AR > 11) and intricate micro features have been fabricated successfully on cobalt alloy at the most suitable parametric combination, i.e., 7.5 V of machining voltage, feed rate of 0.3 mm/min, and tool rotation of 750RPM with 0.5 M of NaNO3 electrolyte.
{"title":"Generation of high aspect ratio complex micro-features by micro-electrochemical milling employing novel flushing technique","authors":"K. Mishra, B. Sarkar, B. Bhattacharyya","doi":"10.1080/10910344.2021.1971713","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971713","url":null,"abstract":"Abstract Fabrication of high aspect ratio (HAR) complex micro features on high strength temperature resistant (HSTR) alloys is challenging by any conventional or non-conventional machining methods. In this study blind, HAR and complex micro features have been fabricated by micro electrochemical milling (MEM) on HSTR Cobalt alloy (Haynes-188) introducing a new strategic approach with novel flushing technique which could get rid of the need of pulsed DC power supply. Multiphysics simulation of the rotating micro-tool at different rpm and its impact on effective sludge removal has been analyzed and verified experimentally. In this study, most influencing parameters of MEM like voltage, feed rate, rpm of tool and milling layer depth have been selected to investigate their effects on the machining responses like width overcut, machined depth and surface roughness on Haynes-188 alloy. Comparison has also been made with constant and pulsed DC power source to know the influence of these process parameters on the MEM responses. Finally, several linear and non-linear blind, HAR (AR > 11) and intricate micro features have been fabricated successfully on cobalt alloy at the most suitable parametric combination, i.e., 7.5 V of machining voltage, feed rate of 0.3 mm/min, and tool rotation of 750RPM with 0.5 M of NaNO3 electrolyte.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45763948","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 : 2021-10-25DOI: 10.1080/10910344.2021.1971708
Houssem Ben Boubaker, K. Djaka, A. Moufki, M. Nouari, P. Laheurte, A. Tidu
Abstract In this work, the effect of the crystallographic anisotropy on machining forces is studied through a thermomechanical approach based on rate sensitive plasticity based model. A crystal plasticity framework is adopted to formulate the required constitutive equations. The present approach takes into account the material thermoviscoplastic response, the shear strain rate distribution in the primary shear zone and their effects on the lattice rotation. The machining forces as well as the corresponding specific energies are calculated using two methods: (a) the total power minimization procedure and (b) the Merchant shear angle procedure. The proposed model is validated using cutting force data available in the literature. Then, it is used to gain insight into the effect of the crystallographic anisotropy on machining forces. According to the results, a strong dependence of the machining forces to the crystallographic orientations is obtained. The model is also used to analyze the of the cutting velocity on the shearing along crystallographic slip systems through the material thermomechanical response. In addition, it is observed that, compared to the total power minimization procedure, the Merchant shear angle procedure allows capturing the specific cutting energy trends due to the crystallographic anisotropy, in terms of peaks and valleys.
{"title":"Thermomechanical modeling of crystallographic anisotropy effect on machining forces based on crystal plasticity framework","authors":"Houssem Ben Boubaker, K. Djaka, A. Moufki, M. Nouari, P. Laheurte, A. Tidu","doi":"10.1080/10910344.2021.1971708","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971708","url":null,"abstract":"Abstract In this work, the effect of the crystallographic anisotropy on machining forces is studied through a thermomechanical approach based on rate sensitive plasticity based model. A crystal plasticity framework is adopted to formulate the required constitutive equations. The present approach takes into account the material thermoviscoplastic response, the shear strain rate distribution in the primary shear zone and their effects on the lattice rotation. The machining forces as well as the corresponding specific energies are calculated using two methods: (a) the total power minimization procedure and (b) the Merchant shear angle procedure. The proposed model is validated using cutting force data available in the literature. Then, it is used to gain insight into the effect of the crystallographic anisotropy on machining forces. According to the results, a strong dependence of the machining forces to the crystallographic orientations is obtained. The model is also used to analyze the of the cutting velocity on the shearing along crystallographic slip systems through the material thermomechanical response. In addition, it is observed that, compared to the total power minimization procedure, the Merchant shear angle procedure allows capturing the specific cutting energy trends due to the crystallographic anisotropy, in terms of peaks and valleys.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-10-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42210051","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 : 2021-10-06DOI: 10.1080/10910344.2021.1971710
L. Gopinath, S. Jerome, B. Gopalsamy
Abstract The nominal cutting contour for the thin wall deviates in response to the cutting forces during the end milling process. Elimination of mass in the milling process links to loss of stiffness, which favors the wall to deflect and promote error. This article proposes a novel way of generating rigidity during the process of milling. The tool paths were drafted to mill away mass in the central region and make corrugations at the edges simultaneously. This approach mitigated the thin wall deformation. Comparison experiments were conducted to analyze between open wall conventional type (OWC) and end corrugated pillar type (ECP). Force polygons were constructed to evaluate the effectiveness of machining. The experiments resulted in 36% more effectiveness in up milling and with 93% in down milling. An increase in the cutting effectiveness exhibited error-free and minimized cutting point deviation at the top of the wall. Eventually, the error diminished as the tool traversed to the bottom edge of the wall.
{"title":"Mitigation of cutting point deviation by generating provisional corrugations during milling of thin walls","authors":"L. Gopinath, S. Jerome, B. Gopalsamy","doi":"10.1080/10910344.2021.1971710","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971710","url":null,"abstract":"Abstract The nominal cutting contour for the thin wall deviates in response to the cutting forces during the end milling process. Elimination of mass in the milling process links to loss of stiffness, which favors the wall to deflect and promote error. This article proposes a novel way of generating rigidity during the process of milling. The tool paths were drafted to mill away mass in the central region and make corrugations at the edges simultaneously. This approach mitigated the thin wall deformation. Comparison experiments were conducted to analyze between open wall conventional type (OWC) and end corrugated pillar type (ECP). Force polygons were constructed to evaluate the effectiveness of machining. The experiments resulted in 36% more effectiveness in up milling and with 93% in down milling. An increase in the cutting effectiveness exhibited error-free and minimized cutting point deviation at the top of the wall. Eventually, the error diminished as the tool traversed to the bottom edge of the wall.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46184117","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 : 2021-09-16DOI: 10.1080/10910344.2021.1971709
M. Javidikia, Morteza Sadeghifar, V. Songmene, M. Jahazi
Abstract The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed ( ), feed rate ( ), depth of cut ( ), tool nose radius ( ), side cutting edge angle (SCEA), and back rake angle (BRA). A 3D finite element (FE) model was developed to predict MT, MFs, and ASRS for different turning environments and parameters and was validated by experimental measurements. The results showed that increasing feed rate led to a higher tensile ASRS while using tools with a nose radius of 0.4 resulted in lower ASRS. In addition, the deviation of SCEA from 0° to positive or negative values caused higher tensile ASRS. ASRS increased with decreasing BRA from 0° to –15°. The variation of ASRS was found to be more sensitive to thermal effects than to mechanical ones. The results further confirmed that in a turning process, the competition between the machining forces and temperature was the fundamental factor that determined the extent of residual stresses.
{"title":"3D FE modeling and experimental analysis of residual stresses and machining characteristics induced by dry, MQL, and wet turning of AA6061-T6","authors":"M. Javidikia, Morteza Sadeghifar, V. Songmene, M. Jahazi","doi":"10.1080/10910344.2021.1971709","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971709","url":null,"abstract":"Abstract The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed ( ), feed rate ( ), depth of cut ( ), tool nose radius ( ), side cutting edge angle (SCEA), and back rake angle (BRA). A 3D finite element (FE) model was developed to predict MT, MFs, and ASRS for different turning environments and parameters and was validated by experimental measurements. The results showed that increasing feed rate led to a higher tensile ASRS while using tools with a nose radius of 0.4 resulted in lower ASRS. In addition, the deviation of SCEA from 0° to positive or negative values caused higher tensile ASRS. ASRS increased with decreasing BRA from 0° to –15°. The variation of ASRS was found to be more sensitive to thermal effects than to mechanical ones. The results further confirmed that in a turning process, the competition between the machining forces and temperature was the fundamental factor that determined the extent of residual stresses.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46823030","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 : 2021-09-09DOI: 10.1080/10910344.2021.1971712
Yu Su, W. Gao, Haifeng Jiang, Zhiqiang Liu
Abstract Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling force, tool wear and oil mist concentration. Four inner/outer fluid combinations were employed in the study, namely, water/LB2000, multiwalled carbon nanotubes (MWCNTs)-water nanofluid/LB2000, water/MWCNTs-LB2000 nanofluid and MWCNTs-water nanofluid/MWCNTs-LB2000 nanofluid. For the analysis of the performance of CES milling, the charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. The results show that MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling from the view point of machining and environmental performances because of superior charging property, atomization stability and friction-reducing effect of nanoparticles. Highlights The performance of CES milling using different inner/outer fluid combinations was studied in terms of milling force, tool wear and oil mist concentration. The charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling.
{"title":"Experimental investigation on the performance of composite electrostatic spraying milling using different inner/outer fluid combinations","authors":"Yu Su, W. Gao, Haifeng Jiang, Zhiqiang Liu","doi":"10.1080/10910344.2021.1971712","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971712","url":null,"abstract":"Abstract Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling force, tool wear and oil mist concentration. Four inner/outer fluid combinations were employed in the study, namely, water/LB2000, multiwalled carbon nanotubes (MWCNTs)-water nanofluid/LB2000, water/MWCNTs-LB2000 nanofluid and MWCNTs-water nanofluid/MWCNTs-LB2000 nanofluid. For the analysis of the performance of CES milling, the charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. The results show that MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling from the view point of machining and environmental performances because of superior charging property, atomization stability and friction-reducing effect of nanoparticles. Highlights The performance of CES milling using different inner/outer fluid combinations was studied in terms of milling force, tool wear and oil mist concentration. The charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45186433","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 : 2021-09-07DOI: 10.1080/10910344.2021.1971714
Roan M. Kirwin, M. Jahan
Abstract Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively. The objective of this study is to investigate effects of non-electrical parameters on the geometric and profile accuracies as well as surface and subsurface characteristics during WEDM of Ti-6Al-4V alloy. A complex part including corners with 45°, 90°, and 112.5° as well as thin wall section for measuring the kerf accuracy was designed. It is found that the profile accuracy improves as the wire tension increases. However, too high wire tension results in curved path in the sharp corners. The effect of wire tension is more pronounced on the workpiece with higher thickness. Too high wire feed rate reduces the accuracy for target angles, especially for lower thickness of workpiece. The kerf width is smaller for thinner workpiece and improves with lower wire feed rate and wire tension. While the wire tension and wire feed rate do not have an impact on surface roughness, higher surface feed rate increases surface roughness. Higher wire tensions lead to higher surface cracking due to more rapid cooling. With increase of surface feed, the percentage of arcing pulses increases due to increased instability, which results in rougher surface and increased percentage of beta phases at the subsurface.
{"title":"Effects of non-electrical parameters on profile accuracies and surface characteristics during wire-EDM of titanium alloy","authors":"Roan M. Kirwin, M. Jahan","doi":"10.1080/10910344.2021.1971714","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971714","url":null,"abstract":"Abstract Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively. The objective of this study is to investigate effects of non-electrical parameters on the geometric and profile accuracies as well as surface and subsurface characteristics during WEDM of Ti-6Al-4V alloy. A complex part including corners with 45°, 90°, and 112.5° as well as thin wall section for measuring the kerf accuracy was designed. It is found that the profile accuracy improves as the wire tension increases. However, too high wire tension results in curved path in the sharp corners. The effect of wire tension is more pronounced on the workpiece with higher thickness. Too high wire feed rate reduces the accuracy for target angles, especially for lower thickness of workpiece. The kerf width is smaller for thinner workpiece and improves with lower wire feed rate and wire tension. While the wire tension and wire feed rate do not have an impact on surface roughness, higher surface feed rate increases surface roughness. Higher wire tensions lead to higher surface cracking due to more rapid cooling. With increase of surface feed, the percentage of arcing pulses increases due to increased instability, which results in rougher surface and increased percentage of beta phases at the subsurface.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2021-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45293007","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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