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前沿新材料,产业基础能力,尖端科技,材料基因工程,双循环,碳达峰与碳中和 1

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Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

《机械工程前沿(英文)》 2013年 第8卷 第2期   页码 187-200 doi: 10.1007/s11465-013-0262-x

摘要:

Machining of plastic materials has become increasingly important in any engineering industry subsequently the prediction of cutting forces. Forces quality has greater influence on components, which are coming in contact with each other. So it becomes necessary to measure and study machined forces and its behavior. In this research work, experimental investigations are conducted to determine the effects of cutting conditions and tool geometry on the cutting forces in the turning of the unidirectional glass fiber reinforced plastics (UD-GFRP) composites. In this experimental study, carbide tool (K10) having different tool nose radius and tool rake angle is used. Experiments are conducted based on the established Taguchi’s technique L18 orthogonal array on a lathe machine. It is found that the depth of cut is the cutting parameter, which has greater influence on cutting forces. The effect of the tool nose radius and tool rake angles on the cutting forces are also considerably significant. Based on statistical analysis, multiple regression model for cutting forces is derived with satisfactory coefficient (R2). This model proved to be highly preferment for predicting cutting forces.

关键词: unidirectional glass fiber reinforced plastics (UD-GFRP) composites     machining     cutting forces (tangential     feed and radial force)     ANOVA     regression modeling     carbide tool (K10)    

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

《机械工程前沿(英文)》 2017年 第12卷 第2期   页码 203-214 doi: 10.1007/s11465-017-0421-6

摘要:

Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

关键词: 3D finite element modeling     micro end-milling     cutting force     chip formation     burr formation    

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

《机械工程前沿(英文)》 2020年 第15卷 第4期   页码 631-644 doi: 10.1007/s11465-020-0599-x

摘要: The ever-increasing requirements for the scalable manufacturing of atomic-scale devices emphasize the significance of developing atomic-scale manufacturing technology. The mechanism of a single atomic layer removal in cutting is the key basic theoretical foundation for atomic-scale mechanical cutting. Material anisotropy is among the key decisive factors that could not be neglected in cutting at such a scale. In the present study, the crystallographic orientation effect on the cutting-based single atomic layer removal of monocrystalline copper is investigated by molecular dynamics simulation. When undeformed chip thickness is in the atomic scale, two kinds of single atomic layer removal mechanisms exist in cutting-based single atomic layer removal, namely, dislocation motion and extrusion, due to the differing atomic structures on different crystallographic planes. On close-packed crystallographic plane, the material removal is dominated by the shear stress-driven dislocation motion, whereas on non-close packed crystallographic planes, extrusion-dominated material removal dominates. To obtain an atomic, defect-free processed surface, the cutting needs to be conducted on the close-packed crystallographic planes of monocrystalline copper.

关键词: ACSM     single atomic layer removal mechanism     crystallographic orientation effect     mechanical cutting     Manufacturing III    

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

《机械工程前沿(英文)》 2020年 第15卷 第1期   页码 81-88 doi: 10.1007/s11465-019-0561-y

摘要: Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.

关键词: tool friction     minimum cutting thickness     finite element method     tool edge radius     micro cutting    

不同立杆高度毛竹材弦切面的润湿性能研究

张巧玲,周洪伟,梁廷斌,仝雪艳,曾钦志

《中国工程科学》 2014年 第16卷 第4期   页码 56-59

摘要:

本文研究了H2O、酚醛树脂胶黏剂(PF)、脲醛树脂胶黏剂(UF)和改性大豆蛋白胶(MSA)在毛竹材不同立杆高度弦切面的润湿性能,通过测定这些润湿液体在竹材弦切面上的接触角,建立润湿液体在毛竹材弦切面的动态润湿模型,分析毛竹材的不同高度对润湿液体动态润湿性能的影响,并对比分析各种润湿液体在毛竹材弦切面的润湿性能差异。

关键词: 毛竹     立杆高度     弦切面     接触角     润湿性    

难加工材料高速切削力非线性特征规律的最大熵谱分析与小波分析

龙震海,王西彬,王好臣

《中国工程科学》 2004年 第6卷 第10期   页码 28-31

摘要:

在切削速度范围157~1000 m/min内,综合应用析因试验与速度单因素试验,对航空用难加工材料2Cr13马氏体不锈钢进行了高速干式铣削试验。在分析其切削力显著性影响因素的基础上,对切削力随机信号进行了现代谱分析与小波分析。研究结果表明,高速切削马氏体不锈钢材料时,切削速度和每齿进给量之间的交互作用对切削力有显著影响;铣削深度和每齿进给量之间的交互作用在切削力响应信号中表现为低频周期信号;低频周期信号与高频信号叠加后,其波形的振幅将会增大。

关键词: 难加工材料     高速切削     析因设计     Meyer小波变换     Mallat算法    

A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

《机械工程前沿(英文)》 2018年 第13卷 第2期   页码 251-263 doi: 10.1007/s11465-018-0504-z

摘要:

Brittle materials have been widely employed for industrial applications due to their excellent mecha-nical, optical, physical and chemical properties. But obtaining smooth and damage-free surface on brittle materials by traditional machining methods like grinding, lapping and polishing is very costly and extremely time consuming. Ductile mode cutting is a very promising way to achieve high quality and crack-free surfaces of brittle materials. Thus the study of ductile mode cutting of brittle materials has been attracting more and more efforts. This paper provides an overview of ductile mode cutting of brittle materials including ductile nature and plasticity of brittle materials, cutting mechanism, cutting characteristics, molecular dynamic simulation, critical undeformed chip thickness, brittle-ductile transition, subsurface damage, as well as a detailed discussion of ductile mode cutting enhancement. It is believed that ductile mode cutting of brittle materials could be achieved when both crack-free and no subsurface damage are obtained simultaneously.

关键词: ductile mode cutting     brittle materials     critical undeformed chip thickness     brittle-ductile transition     subsurface damage     molecular dynamic simulation    

Cutting performance of surgical electrodes by constructing bionic microstriped structures

《机械工程前沿(英文)》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0728-9

摘要: Surgical electrodes rely on thermal effect of high-frequency current and are a widely used medical tool for cutting and coagulating biological tissue. However, tissue adhesion on the electrode surface and thermal injury to adjacent tissue are serious problems in surgery that can affect cutting performance. A bionic microstriped structure mimicking a banana leaf was constructed on the electrode via nanosecond laser surface texturing, followed by silanization treatment, to enhance lyophobicity. The effect of initial, simple grid-textured, and bionic electrodes with different wettabilities on tissue adhesion and thermal injury were investigated using horizontal and vertical cutting modes. Results showed that the bionic electrode with high lyophobicity can effectively reduce tissue adhesion mass and thermal injury depth/area compared with the initial electrode. The formation mechanism of adhered tissue was discussed in terms of morphological features, and the potential mechanism for antiadhesion and heat dissipation of the bionic electrode was revealed. Furthermore, we evaluated the influence of groove depth on tissue adhesion and thermal injury and then verified the antiadhesion stability of the bionic electrode. This study demonstrates a promising approach for improving the cutting performance of surgical electrodes.

关键词: surgical electrodes     tissue adhesion     thermal injury     bionic structures     cutting performance     medical tools    

Large eddy simulation of turbulent buffet forces in flow induced vibration

XI Zhide, CHENG Bingde, LI Pengzhou

《能源前沿(英文)》 2008年 第2卷 第4期   页码 524-527 doi: 10.1007/s11708-008-0099-x

摘要: The pressure pulse filter and Smagorinsky sub-grid stress model of the Large Eddy Simulation (LES) are introduced. The fluid field in the annular plenum between the pressure vessel and the core barrel of the1:5 model in the second phase of Qinshan Nuclear Power Plant is simulated, and the distribution of the total pressure in the space and time domains is obtained. The results show that the Power Spectrum Density (PSD) of LES from the calculation and the test are in the same quantity order. Thus, the pressure of LES can be a load to stimulate the barrel vibration.

关键词: Spectrum Density     Smagorinsky sub-grid     vibration     calculation     Qinshan Nuclear    

Edge preparation methods for cutting tools: a review

《机械工程前沿(英文)》 2023年 第18卷 第4期 doi: 10.1007/s11465-023-0766-y

摘要: Edge preparation can remove cutting edge defects, such as burrs, chippings, and grinding marks, generated in the grinding process and improve the cutting performance and service life of tools. Various edge preparation methods have been proposed for different tool matrix materials, geometries, and application requirements. This study presents a scientific and systematic review of the development of tool edge preparation technology and provides ideas for its future development. First, typical edge characterization methods, which associate the microgeometric characteristics of the cutting edge with cutting performance, are briefly introduced. Then, edge preparation methods for cutting tools, in which materials at the cutting edge area are removed to decrease defects and obtain a suitable microgeometry of the cutting edge for machining, are discussed. New edge preparation methods are explored on the basis of existing processing technologies, and the principles, advantages, and limitations of these methods are systematically summarized and analyzed. Edge preparation methods are classified into two categories: mechanical processing methods and nontraditional processing methods. These methods are compared from the aspects of edge consistency, surface quality, efficiency, processing difficulty, machining cost, and general availability. In this manner, a more intuitive understanding of the characteristics can be gained. Finally, the future development direction of tool edge preparation technology is prospected.

关键词: edge preparation method     preparation principle     cutting edge geometry     edge characterization     tool performance    

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

《机械工程前沿(英文)》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0729-8

摘要: When ultrasonically cutting honeycomb core curved parts, the tool face of the straight blade must be along the curved surface’s tangent direction at all times to ensure high-quality machining of the curved surface. However, given that the straight blade is a nonstandard tool, the existing computer-aided manufacturing technology cannot directly realize the above action requirement. To solve this problem, this paper proposed an algorithm for extracting a straight blade real-time tool face vector from a 5-axis milling automatically programmed tool location file, which can realize the tool location point and tool axis vector conversion from the flat end mill to the straight blade. At the same time, for the multi-solution problem of the rotation axis, the dependent axis rotation minimization algorithm was introduced, and the spindle rotation algorithm was proposed for the tool edge orientation problem when the straight blade is used to machine the curved part. Finally, on the basis of the MATLAB platform, the dependent axis rotation minimization algorithm and spindle rotation algorithm were integrated and compiled, and the straight blade ultrasonic cutting honeycomb core postprocessor was then developed. The model of the machine tool and the definition of the straight blade were conducted in the VERICUT simulation software, and the simulation machining of the equivalent entity of the honeycomb core can then be realized. The correctness of the numerical control program generated by the postprocessor was verified by machining and accuracy testing of the two designed features. Observation and analysis of the simulation and experiment indicate that the tool pose is the same under each working condition, and the workpieces obtained by machining also meet the corresponding accuracy requirements. Therefore, the postprocessor developed in this paper can be well adapted to the honeycomb core ultrasonic cutting machine tool and realize high-quality and high-efficient machining of honeycomb core composites.

关键词: honeycomb core     straight blade     ultrasonic cutting     tool pose     postprocessor    

Improved analytical model for residual stress prediction in orthogonal cutting

null

《机械工程前沿(英文)》 2014年 第9卷 第3期   页码 249-256 doi: 10.1007/s11465-014-0310-1

摘要:

The analytical model of residual stress in orthogonal cutting proposed by Jiann is an important tool for residual stress prediction in orthogonal cutting. In application of the model, a problem of low precision of the surface residual stress prediction is found. By theoretical analysis, several shortages of Jiann’s model are picked out, including: inappropriate boundary conditions, unreasonable calculation method of thermal stress, ignorance of stress constraint and cyclic loading algorithm. These shortages may directly lead to the low precision of the surface residual stress prediction. To eliminate these shortages and make the prediction more accurate, an improved model is proposed. In this model, a new contact boundary condition between tool and workpiece is used to make it in accord with the real cutting process; an improved calculation method of thermal stress is adopted; a stress constraint is added according to the volume-constancy of plastic deformation; and the accumulative effect of the stresses during cyclic loading is considered. At last, an experiment for measuring residual stress in cutting AISI 1045 steel is conducted. Also, Jiann’s model and the improved model are simulated under the same conditions with cutting experiment. The comparisons show that the surface residual stresses predicted by the improved model is closer to the experimental results than the results predicted by Jiann’s model.

关键词: residual stress     analytical model     orthogonal cutting     cutting force     cutting temperature    

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

《机械工程前沿(英文)》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0715-1

摘要: Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments. In this study, a high-performance ultrasonic elliptical vibration cutting (UEVC) system is developed to solve the precision machining problem of tungsten heavy alloy. A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed, and its design process is greatly simplified. The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes. A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus, which is verified by finite element method. The vibration unit can display different three-degree-of-freedom (3-DOF) UEVC characteristics by adjusting the corresponding position of the unit and workpiece. A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit, which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2 μm. Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system, which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy.

关键词: tungsten heavy alloy     ultrasonic elliptical vibration cutting     Timoshenko’s theory     resonant mode of bending     finite element method    

Depth of cut models for multipass abrasive waterjet cutting of alumina ceramics with nozzle oscillation

Jun WANG

《机械工程前沿(英文)》 2010年 第5卷 第1期   页码 19-32 doi: 10.1007/s11465-009-0082-1

摘要: An experimental study of the depth of cut in multipass abrasive waterjet (AWJ) cutting of alumina ceramics with controlled nozzle oscillation is presented. It is found that this cutting technique can significantly increase the depth of cut by an average of 50.8% as compared to single pass cutting without nozzle oscillation under the corresponding cutting conditions and within the same cutting time. Predictive models for the depth of cut are then developed. The modelling process starts with single pass cutting using a dimensional analysis technique and the particle erosion theories applied to alumina ceramics, before progressing to the development of the models for multipass cutting. The models are finally assessed both qualitatively and quantitatively with experimental data. It is shown that the model predictions are in good agreement with the experimental data with the average deviations of about 1%.

关键词: abrasive waterjet     engineering ceramics     depth of cut     cutting performance     nozzle oscillation     machining    

Analysis and comparison of laser cutting performance of solar float glass with different scanning modes

Wenyuan LI, Yu HUANG, Youmin RONG, Long CHEN, Guojun ZHANG, Zhangrui GAO

《机械工程前沿(英文)》 2021年 第16卷 第1期   页码 97-110 doi: 10.1007/s11465-020-0600-8

摘要: Cutting quality and efficiency have always been important indicators of glass laser cutting. Laser scanning modes have two kinds, namely, the spiral and concentric circle scanning modes. These modes can achieve high-performance hole cutting of thick solar float glass using a 532-nm nanosecond laser. The mechanism of the glass laser cutting under these two different scanning modes has been described. Several experiments are conducted to explore the effect of machining parameters on cutting efficiency and quality under these two scanning modes. Results indicate that compared with the spiral scanning mode, the minimum area of edge chipping (218340 µm ) and the minimum Ra (3.01 µm) in the concentric circle scanning mode are reduced by 9.4% and 16.4% respectively. Moreover, the best cutting efficiency scanning mode is 14.2% faster than that in the spiral scanning mode. The best parameter combination for the concentric circle scanning mode is as follows: Scanning speed: 2200 mm/s, number of inner circles: 6, and circle spacing: 0.05 mm. This parameter combination reduces the chipping area and sidewall surface roughness by 8.8% and 9.6% respectively at the same cutting efficiency compared with the best spiral processing parameters. The range of glass processing that can be achieved in the concentric circle scanning mode is wider than that in the spiral counterpart. The analyses of surface topography, white spots, microstructures, and sidewall surface element composition are also performed. The study concluded that the concentric circle scanning mode shows evident advantages in the performance of solar float glass hole cutting.

关键词: laser cutting     solar float glass     scanning mode     surface quality     cutting efficiency    

标题 作者 时间 类型 操作

Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

期刊论文

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

期刊论文

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

期刊论文

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

期刊论文

不同立杆高度毛竹材弦切面的润湿性能研究

张巧玲,周洪伟,梁廷斌,仝雪艳,曾钦志

期刊论文

难加工材料高速切削力非线性特征规律的最大熵谱分析与小波分析

龙震海,王西彬,王好臣

期刊论文

A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

期刊论文

Cutting performance of surgical electrodes by constructing bionic microstriped structures

期刊论文

Large eddy simulation of turbulent buffet forces in flow induced vibration

XI Zhide, CHENG Bingde, LI Pengzhou

期刊论文

Edge preparation methods for cutting tools: a review

期刊论文

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

期刊论文

Improved analytical model for residual stress prediction in orthogonal cutting

null

期刊论文

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

期刊论文

Depth of cut models for multipass abrasive waterjet cutting of alumina ceramics with nozzle oscillation

Jun WANG

期刊论文

Analysis and comparison of laser cutting performance of solar float glass with different scanning modes

Wenyuan LI, Yu HUANG, Youmin RONG, Long CHEN, Guojun ZHANG, Zhangrui GAO

期刊论文