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Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

《机械工程前沿(英文)》 2014年 第9卷 第2期   页码 106-119 doi: 10.1007/s11465-014-0301-2

摘要:

Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the tool wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

关键词: tool wear     nickel based super-alloy     wear mechanism    

Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

《机械工程前沿(英文)》 2012年 第7卷 第4期   页码 410-416 doi: 10.1007/s11465-012-0341-4

摘要:

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

关键词: tool vibration     magneto rheological damper     hard turning     surface finish     tool wear    

基于判别扩散映射分析的内蕴特征提取方法在刀具磨损评估中的应用 None

Yi-xiang HUANG, Xiao LIU, Cheng-liang LIU, Yan-ming LI

《信息与电子工程前沿(英文)》 2018年 第19卷 第11期   页码 1352-1361 doi: 10.1631/FITEE.1601512

摘要: 针对铣削加工刀具磨损评估,提出一种基于判别扩散映射分析的方法。判别扩散映射分析(discriminant diffusion maps analysis,DDMA)用于时频域特征提取融合与维度缩减。通过保持内蕴特征空间的扩散距离,耦合时频域特征和判别内核,提取有效信息。该方法包含3个步骤:(1)信号处理与特征提取;(2)内蕴维度估计;(3)基于扩散距离保持的特征融合实现。将该方法应用于数控加工中心主轴驱动电流信号,评估刀具磨损状态。与常见主成分分析方法相比,该方法能更好保持刀具磨损状态相关的有用内蕴信息,大大降低与刀具磨损相关的特征维度,并可直接应用于大多数工业数控加工中心,方便获取电流信号实际情况。

关键词: 刀具状态监测;流形学习;降维;扩散映射分析;内蕴特征提取    

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

《机械工程前沿(英文)》 2011年 第6卷 第4期   页码 419-428 doi: 10.1007/s11465-011-0246-7

摘要:

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of ultrasonic vibration of workpiece on the characteristics of Electrical Discharge Machining (EDM) process of FW4 Welding Metal in comparison with the conventional EDM process. The studied process characteristics included the material removal rate (MRR), tool wear ratio (TWR), and surface roughness (Ra and Rmax) of the workpiece after the EDM and ultrasonic assisted EDM (US-EDM) processes. The experiments performed under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The experimental results show that in short pulse on-times, material removal rate in the US-EDM process is approximately quadruple than that of the EDM process. On the contrary, in the long pulse on-times, ultrasonic vibration of work??piece leads to the reduction in the MRR. On the other hand, in short pulse on-times, the TWR in the US-EDM process is lower than that of in the EDM process, and this condition reverses with increase in the pulse on-time. Furthermore, the surface roughness of the workpiece machined by EDM process is slightly lower than that of applied to the US-EDM process.

关键词: electrical discharge machining (EDM)     material removal rate (MRR)     tool wear ratio (TWR)     surface roughness    

Facile synthesis of polyaniline nanorods to simultaneously enhance the mechanical properties and wear

《化学科学与工程前沿(英文)》 2023年 第17卷 第9期   页码 1254-1266 doi: 10.1007/s11705-023-2297-3

摘要: To enhance the mechanical properties and wear resistance of epoxy resin, polyaniline nanorods were first synthesized using a facile route, and then introduced into the epoxy matrix to yield composites via solution mixing. Several measurements were conducted to investigate the phase structures and compositions of polyaniline nanorods, and their positive influences on the mechanical and tribological properties of epoxy resin were also characterized. The results confirmed that the as-synthesized polyaniline exhibited representative rod-like morphologies and dispersed well in the epoxy matrix, leading to significant enhancements in the tensile strength and elastic modulus of epoxy composites. The highest values of 110.33 MPa and 2.04 GPa were obtained by adding 5%–7% polyaniline nanorods, which were 43% and 62% higher than the pure sample, respectively. The wear rate was increased first and then decreased along with polyaniline nanorods, presenting the lowest value of 2.12 × 10−5 mm3·Nm–1 by adding 5% filler, which was markedly reduced by ca. 70% compared to the control sample. Finally, the possible wear mechanism was proposed and discussed in detail. This study tried to broaden the applications of polyaniline nanorods in the field of tribology.

关键词: epoxy resin     polyaniline nanorods     mechanical property     tribological performance     wear mechanism    

Integrated slipper retainer mechanism to eliminate slipper wear in high-speed axial piston pumps

《机械工程前沿(英文)》 doi: 10.1007/s11465-021-0657-z

摘要: The power density of axial piston pumps can greatly benefit from increasing the speed level. However, traditional slippers in axial piston pumps are exposed to continuous sliding on the swash plate, suffering from serious wear at high rotational speeds. Therefore, this paper presents a new integrated slipper retainer mechanism for high-speed axial piston pumps, which can avoid direct contact between the slippers and the swash plate and thereby eliminate slipper wear under severe operating conditions. A lubrication model was developed for this specific slipper retainer mechanism, and experiments were carried out on a pump prototype operating at high rotational speed up to 10000 r/min. Experimental results qualitatively validated the theoretical model and confirmed the effectiveness of the new slipper design.

关键词: axial piston pump     high speed     slipper wear     slipper design     retainer     lubrication model    

Enhanced wear prediction of tunnel boring machine disc cutters for accurate remaining useful life estimation

《结构与土木工程前沿(英文)》 2024年 第18卷 第4期   页码 642-662 doi: 10.1007/s11709-024-1058-2

摘要: In tunnel construction with tunnel boring machines (TBMs), accurate prediction of the remaining useful life (RUL) of disc cutters is critical for timely maintenance and replacement to avoid delays and cost overruns. This paper introduces a novel hybrid model, integrating fundamental and data-driven approaches, to enhance wear prediction of TBM disc cutters and enable accurate RUL estimation. The fundamental model is improved by incorporating composite wear mechanisms and load estimation techniques, showcasing superior prediction accuracy compared to single-mechanism models. Additionally, the hybrid model innovatively incorporates a data-driven supplementary residual term into the improved fundamental model, leading to a high-performance wear prediction model. Using actual field data from a highway tunnel project in Shenzhen, the performance of the hybrid model is rigorously tested and compared with pure fundamental and data-driven models. The hybrid model outperforms the other models, achieving the highest accuracy in predicting TBM disc cutter wear (mean absolute error (MAE) = 0.53, root mean square error (RMSE) = 0.64). Furthermore, this study thoroughly analyzes the hybrid model’s generalization capability, revealing significant impacts of geological conditions on prediction accuracy. The model’s generalization capability is also improved by expanding and updating the data sets. The RUL estimation results provided by the hybrid model are straightforward and effective, making it a valuable tool by which construction staff can monitor TBM disc cutters.

关键词: tunnel boring machine     disc cutter     wear prediction     remaining useful life     field data     hybrid model    

Energy saving design of the machining unit of hobbing machine tool with integrated optimization

《机械工程前沿(英文)》 2022年 第17卷 第3期 doi: 10.1007/s11465-022-0694-2

摘要: The machining unit of hobbing machine tool accounts for a large portion of the energy consumption during the operating phase. The optimization design is a practical means of energy saving and can reduce energy consumption essentially. However, this issue has rarely been discussed in depth in previous research. A comprehensive function of energy consumption of the machining unit is built to address this problem. Surrogate models are established by using effective fitting methods. An integrated optimization model for reducing tool displacement and energy consumption is developed on the basis of the energy consumption function and surrogate models, and the parameters of the motor and structure are considered simultaneously. Results show that the energy consumption and tool displacement of the machining unit are reduced, indicating that energy saving is achieved and the machining accuracy is guaranteed. The influence of optimization variables on the objectives is analyzed to inform the design.

关键词: energy saving design     energy consumption     machining unit     integrated optimization     machine tool    

Development of a new wear resistant coating by arc spraying of a steel-based cored wire

Lidong ZHAO, Pia KUTSCHMANN, Binyou FU, Dingyong HE

《机械工程前沿(英文)》 2009年 第4卷 第1期   页码 1-4 doi: 10.1007/s11465-009-0012-2

摘要: In the present study, a cored wire of 304 L stainless steel as sheath material and NiB and WC-12Co as filler materials was designed and deposited to produce a new wear resistant coating containing amorphous phase by arc spraying. The microstructure of the coating was investigated. The porosity and hardness of the coating were determined. The wear performance of the coating was evaluated. The XRD and TEM analyses showed that there are high volume of amorphous phase and very fine crystalline grains in the coating. DTA measurements revealed that the crystallization of the amorphous phase occurred at 579.2°C. Because metallurgical processes for single droplets were non-homogenous during spraying, the lamellae in the coating have different hardness values, which lie between about 700 and 1250 HV . The abrasive wear test showed that the new Fe-based coating was very wear resistant.

关键词: amorphous phase     arc spraying     microstructure     wear     cored wire    

Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and resistance to

Sawan KUMAR, Ajitanshu VEDRTNAM, S. J. PAWAR

《结构与土木工程前沿(英文)》 2019年 第13卷 第6期   页码 1446-1462 doi: 10.1007/s11709-019-0568-9

摘要: The present work reports the inclusion of different proportions of Mango/Sheesham/Mahogany/Babool dust to polypropylene for improving mechanical, wear behavior and biodegradability of wood-plastic composite (WPC). The wood dust (10%, 15%, 20% by weight) was mixed with polypropylene granules and WPCs were prepared using an injection molding technique. The mechanical, wear, and morphological characterizations of fabricated WPCs were carried out using standard ASTM methods, pin on disk apparatus, and scanning electron microscopy (SEM), respectively. Further, the biodegradability and resistance to natural weathering of WPCs were evaluated following ASTM D5338-11 and ASTM D1435-99, respectively. The WPCs consisting of Babool and Sheesham dust were having superior mechanical properties whereas the WPCs consisting of Mango and Mahogany were more wear resistant. It was found that increasing wood powder proportion results in higher Young’s modulus, lesser wear rate, and decreased stress at break. The WPCs made of Sheesham dust were least biodegradable. It was noticed that the biodegradability corresponds with resistance to natural weathering; more biodegradable WPCs were having the lesser resistance to natural weathering.

关键词: wood-plastic composites     mechanical testing     wear     biodegradability     injection molding     weathering    

Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

《化学科学与工程前沿(英文)》 2023年 第17卷 第12期   页码 2114-2126 doi: 10.1007/s11705-023-2357-1

摘要: In this study, nickel phyllosilicate was synthesized based on molybdenum disulfide (MoS2@NiPS) by the sol-gel method, and then MoS2@NiPS was used to prepare epoxy composites. The thermal stability, flame retardancy, and frictional performances of epoxy composites were studied. With the addition of 3 wt% MoS2@NiPS, the epoxy composite increased the limiting oxygen index from 23.8% to 26.1% and reduced the vertical burning time from 166 s for epoxy resin to 35 s. The residual char of the epoxy composite increased from 11.8 to 20.2 wt%. MoS2@NiPS promoted the graphitization of the residual char, and facilitated the formation of a dense and continuous char layer, thereby improving the fire safety of epoxy resin. The epoxy composite with 3 wt% MoS2@NiPS had excellent wear resistance property with a wear rate of 2.19 × 10−5 mm3·N–1·m–1, which was 68.8% lower than that of epoxy resin. This study presented a practical approach to improve the frictional and fire resistance of epoxy composites.

关键词: molybdenum disulfide     nickel phyllosilicate     epoxy resin     flame retardancy    

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

《机械工程前沿(英文)》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0719-x

摘要: The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

关键词: grinding     aerospace     difficult-to-machine material     biolubricant     physicochemical property     grindability    

Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

《机械工程前沿(英文)》 2022年 第17卷 第1期   页码 9-9 doi: 10.1007/s11465-021-0665-z

摘要: Gear wear is one of the most common gear failures, which changes the mesh relationship of normal gear. A new mesh relationship caused by gear wear affects meshing excitations, such as mesh stiffness and transmission error, and further increases vibration and noise level. This paper aims to establish the model of mesh relationship and reveal the vibration characteristics of external spur gears with gear wear. A geometric model for a new mesh relationship with gear wear is proposed, which is utilized to evaluate the influence of gear wear on mesh stiffness and unloaded static transmission error (USTE). Based on the mesh stiffness and USTE considering gear wear, a gear dynamic model is established, and the vibration characteristics of gear wear are numerically studied. Comparison with the experimental results verifies the proposed dynamic model based on the new mesh relationship. The numerical and experimental results indicate that gear wear does not change the structure of the spectrum, but it alters the amplitude of the meshing frequencies and their sidebands. Several condition indicators, such as root-mean-square, kurtosis, and first-order meshing frequency amplitude, can be regarded as important bases for judging gear wear state.

关键词: gear wear     mesh relationship     mesh stiffness     transmission error     vibration characteristics    

Correction to: Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and

《结构与土木工程前沿(英文)》 2021年 第15卷 第4期   页码 1071-1071 doi: 10.1007/s11709-021-0736-6

Study on tribological and electrochemistry properties of metal materials in H2O2 solutions

Chengqing YUAN, Li YU, Jian LI, Xinping YAN

《机械工程前沿(英文)》 2012年 第7卷 第1期   页码 93-98 doi: 10.1007/s11465-012-0313-8

摘要:

Hydrogen peroxide (H2O2) is a kind of ideal green propellant. It is crucial to study the wear behavior and failure modes of the metal materials under the strong oxidizing environment of H2O2. This study aims to investigate the wear of rubbing pairs of 2Cr13 stainless steel against 1045 metal in H2O2 solutions, which has a great effect on wear, the decomposition and damage mechanism of materials. The comparison analysis of the friction coefficients, wear mass loss, worn surface topographies and current densities was conducted under different concentrations of H2O2 solutions. There were significant differences in the tribological and electrochemistry properties of the rubbing pairs in different H2O2 solutions.

关键词: hydrogen peroxide     wear     corrosion     wear mechanism    

标题 作者 时间 类型 操作

Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

期刊论文

Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

期刊论文

基于判别扩散映射分析的内蕴特征提取方法在刀具磨损评估中的应用

Yi-xiang HUANG, Xiao LIU, Cheng-liang LIU, Yan-ming LI

期刊论文

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

期刊论文

Facile synthesis of polyaniline nanorods to simultaneously enhance the mechanical properties and wear

期刊论文

Integrated slipper retainer mechanism to eliminate slipper wear in high-speed axial piston pumps

期刊论文

Enhanced wear prediction of tunnel boring machine disc cutters for accurate remaining useful life estimation

期刊论文

Energy saving design of the machining unit of hobbing machine tool with integrated optimization

期刊论文

Development of a new wear resistant coating by arc spraying of a steel-based cored wire

Lidong ZHAO, Pia KUTSCHMANN, Binyou FU, Dingyong HE

期刊论文

Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and resistance to

Sawan KUMAR, Ajitanshu VEDRTNAM, S. J. PAWAR

期刊论文

Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

期刊论文

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

期刊论文

Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

期刊论文

Correction to: Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and

期刊论文

Study on tribological and electrochemistry properties of metal materials in H2O2 solutions

Chengqing YUAN, Li YU, Jian LI, Xinping YAN

期刊论文