scholarly journals Machinability investigation of polymer/GNP nanocomposites in micro-milling

2021 ◽  
Author(s):  
Guoyu Fu ◽  
Dehong Huo ◽  
Islam Shyha ◽  
Fuzhong Sun ◽  
Qiang Gao
Keyword(s):  
High Surface ◽  
Dimensional Accuracy ◽  
Polymer Materials ◽  
Micro Milling ◽  
Machined Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Formation Mode ◽  
Thermal And Electrical Properties ◽  
Advance Knowledge

AbstractNanoparticles such as graphene have been added to various polymer matrices to enhance the mechanical, thermal, and electrical properties of polymer materials that require complex designs on a microscopic scale. Micro-machining is used to process these nanocomposite materials to achieve high surface quality and dimensional accuracy while maintaining high productivity. In this study, a systematic micro-milling experiment was performed on polymer/graphene nanoplatelet (GNP) nanocomposites to advance knowledge of the micro-machinability of these materials. It evaluates the effect of the addition of 0.1wt% GNP nanoparticles on machined surface morphology, chip formation, cutting forces, and tool wear. It is found that the addition of GNP nanoparticles changes the slot edge formation mode from burring mode to chipping mode.

scholarly journals Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

2021 ◽  
Author(s):  
Lukas Seeholzer ◽  
Stefan Süssmaier ◽  
Fabian Kneubühler ◽  
Konrad Wegener
Keyword(s):  
Surface Quality ◽  
Influencing Factors ◽  
Material Properties ◽  
High Surface ◽  
Workpiece Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Surface Temperatures ◽  
Process Forces ◽  
The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

Benchmark test artifacts for selective laser melting – a critical review

2021 ◽  
Vol 15 ◽  
Author(s):  
Weishi Li ◽  
Kuanting Wang ◽  
Shiaofen Fang
Keyword(s):  
Selective Laser Melting ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Melting Process ◽  
Design Guidelines ◽  
Laser Melting ◽  
Specific Test ◽  
Benchmark Test ◽  
High Surface Quality ◽  
Machine Performance

Background: Selective laser melting is the best-established additive manufacturing technology for high-quality metal part manufacturing. However, the widespread acceptance of the technology is still underachieved, especially in critical applications, due to the absence of a thorough understanding of the technology, although several benchmark test artifacts have been developed to characterize the performance of selective laser melting machines. Objective: The objective of this paper is to inspire new designs of benchmark test artifacts to understand the selective laser melting process better and promote the acceptance of the selective laser melting technology. Method: The existing benchmark test artifacts for selective laser melting are analyzed comparatively, and the design guidelines are discussed. Results: The modular approach should still be adopted in designing new benchmark test artifacts in the future, and task-specific test artifacts may also need to be considered further to validate the machine performance for critical applications. The inclusion of the design model in the manufactured artifact, instead of the conformance to the design specifications, should be evaluated after the artifact is measured for the applications requiring high-dimensional accuracy and high surface quality. Conclusion: The benchmark test artifact for selective laser melting is still under development, and a breakthrough of the measuring technology for internal and/or inaccessible features will be beneficial for understanding the technology.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

A Preliminary Study of the Erosion Process in Micro-Machining of Glasses with a Low Pressure Slurry Jet

2008 ◽  
Vol 389-390 ◽  
pp. 375-380 ◽  
Author(s):  
Thai Nguyen ◽  
King Pang ◽  
Jun Wang
Keyword(s):  
Fluid Flow ◽  
High Surface ◽  
Low Pressure ◽  
Outer Diameter ◽  
Micro Machining ◽  
Erosion Process ◽  
Machined Surface ◽  
High Surface Quality ◽  
Accumulation Zone ◽  
Micro Hole

The erosion process in micro-machining of brittle glasses using a low pressure slurry jet is discussed. The process capability of the technique is assessed by examining the machined surface integrity in relation to fluid flow dynamics in micro-hole generations. The holes produced are characterised by a “W” shape in the cross section, while the surface morphology is distinguished by three zones associated with the fluid flow behaviour, i.e. a direct impact zone, a wavy zone and an accumulation zone. The surfaces appear to be smooth and without cracks, indicating a predominance of the ductile mode erosion process. With the increase of pressure, the erosion rates can be enhanced as a result of the expending of the accumulation zone while the outer diameter of the holes remains unchanged. This study shows that this technique can be used for micro-machining with high surface quality, and provides an essential understanding for further research in the avenue.

Barrel Chamber Polishing, Using Electrochemical Theories

2007 ◽  
Vol 364-366 ◽  
pp. 272-279
Author(s):  
Ramezan Ali Mahdavinejad
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Point Of View ◽  
Electrochemical Polishing ◽  
Machining Time ◽  
High Surface Quality ◽  
Surface Polishing ◽  
Complex Shapes ◽  
Complex Parts

Electrochemical polishing is a well-known method in finishing of complex shapes with high surface quality. Inner surface polishing of complex parts with high precision can also be easily done by this method. In this research, barrel chamber’s surface, with numerous serial surface angles, is analyzed so that, according to the various set ups, the optimized polishing parameters are obtained. The comparison between electrochemical polishing and conventional methods from this point of view, shows good advantages of this method, so that, the machining time is more than thirty times less and produces very high surface quality. Besides, the dimensional accuracy of the workpiece repeatability process in this polishing method is noticeable.

Cathode Design of Aero-Engine Blades in Electrochemical Machining Based on Characteristics of Gap Distribution

2009 ◽  
Vol 69-70 ◽  
pp. 248-252 ◽  
Author(s):  
Ji Hua ◽  
Zhi Yong Li
Keyword(s):  
High Surface ◽  
Electrochemical Machining ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Electrode Gap ◽  
Electrolyte Flow ◽  
High Surface Quality ◽  
Cathode Design ◽  
Aero Engine ◽  
Electric Filed

Cathode design is a difficult problem must be faced and solved in ECM. We develop a new numerical approach for cathode design by employing a finite element method and this approach has been applied in the cathode design of aero-engine blades in ECM. The mathematic models of the electric filed and electrolyte flow filed distribution in EMC process are described primarily. Then the realization procedure of this approach is presented，in which the effects of electric filed and electrolyte flow filed distribution within the inter-electrode gap domain are concentrated. In order to verify the machining accuracy of the designed cathodes, the experiments are conducted using an industrial scale electrochemical machining system. The experimental results demonstrate that the machined blade have high surface quality and dimensional accuracy which proves the proposed approach for cathode design of aero-engine blades in ECM is applicable and valuable.

Research on Surface Topography and Roughness of Micro Parts by High Speed Turn-Milling

2014 ◽  
Vol 800-801 ◽  
pp. 607-612 ◽  
Author(s):  
Cheng Zhe Jin ◽  
Rui Fang
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
High Speed ◽  
Orthogonal Experiment ◽  
High Surface ◽  
Cutting Speed ◽  
Machined Surface ◽  
High Surface Quality ◽  
Micro Parts ◽  
Turn Milling

High speed turn-milling has superiority on the productivity and the quality of work pieces, and is more suitable to machine micro-shaft parts and desirable miniature parts based on the turn-milling technology. In this papers adopting orthogonal experiment method cutting experiments of orthogonal turn-milling Aluminum alloy have been done. The relation between turn-milling regimes (cutter rotate speed, axial feed, feed per tooth etc.) and machined surface roughness has been ascertained. Finally, primary and secondary order of cutting regimes impacting surface roughness has more been confirmed through orthogonal experiments variance analysis, the rotate speed of cutter (cutting speed) influence greatly on surface roughness. Through 2-dimension surface topography diagram and 3-dimension surface topography of processed surface, it can be seen that high speed turn-milling processing technology can process micro miniature component of high surface quality, and features excellent development prospect and application value.

Precision Finishing Combined with ELID and MRF

2004 ◽  
Vol 471-472 ◽  
pp. 317-320 ◽  
Author(s):  
Gui Wen Kang ◽  
Fei Hu Zhang ◽  
Shen Dong
Keyword(s):  
High Surface ◽  
Brittle Materials ◽  
Diamond Wheel ◽  
High Surface Quality ◽  
High Productivity ◽  
Elid Grinding ◽  
Grinding Method ◽  
Finishing Process ◽  
Hard And Brittle Materials ◽  
Precision Finishing

ELID grinding is widely used as a high-productivity and super-precision grinding method for hard and brittle materials. It continues grinding stably with metal bonded diamond wheel due to its in-process dressing. Magnetorheological finishing (MRF) is a novel precision finishing process for hard and brittle materials. In this paper, ELID grinding and MRF are adopted to get high surface quality and remove subsurface damage of hard and brittle materials. The results show that this combination gives attention to both efficiency and quality and can be used to replace conventional optics manufacturing.

Finishing of Ceramics in a Single-Disk Lapping Machine Configuration

2010 ◽  
Vol 165 ◽  
pp. 237-243 ◽  
Author(s):  
Adam Barylski ◽  
Mariusz Deja
Keyword(s):  
Rotational Velocity ◽  
High Surface ◽  
Single Layer ◽  
Grit Size ◽  
Technological Parameters ◽  
Machined Surface ◽  
High Surface Quality ◽  
Second Stage ◽  
Single Disk ◽  
Lapping Machine

Lapping of plane surfaces is the technology which allows achieving high surface quality. Kinematics of lapping has the main effect on the flatness of active plane of the lapping tools as well as on the quality and flatness of the machined surface. Lapping machines can be used for grinding without the chuck-related problems as encountered in conventional surface grinding. The configuration of a conventional single-disk lapping machine was modified and the rotational velocity of a workpiece holder can be precisely controlled by a stepper motor. Two types of tools were used for experiments on a modified machine. The first tool was equipped with grinding inserts made of resin and synthetic diamond micrograins (grit size 3/2 m). In the second stage of experiments the single-layer electroplated diamond tool (D107 – grit size 106/90 m) was applied. Ceramic workpieces (Al2O3) were machined on the modified single-disc lapping machine with the use of both tools and with additional loose abrasive. Experimental results of removal rates, technological parameters and kinematical analysis are the subject of the presented paper.

Study on the Milling Technologies of Super-Slender Rod

2013 ◽  
Vol 770 ◽  
pp. 69-73
Author(s):  
Wei Ren ◽  
Wei Yu ◽  
Mao Su Zhou
Keyword(s):  
High Surface ◽  
Difficult Problem ◽  
Machining Process ◽  
Process Scheme ◽  
Machined Surface ◽  
High Surface Quality ◽  
Technology Process ◽  
Cutting Heat ◽  
New Strategy ◽  
Low Stiffness

t is well known that slender rod machining operation is a very difficult problem due to its low stiffness. During slender rod machining process, the deflection, vibration, cutting heat and cutting force of the machined part are the main reasons affecting the product quality. Based on the analysis of current research status of slender rod milling technology, process scheme, milling strategy, clamping fixture and tool designing is carried out in this work. In a roughing milling stage, we create a new strategy of square rod milling, called equilateral milling strategy to eliminating deflection. In finish-milling top waveform stage, a way using semicircle profile cutter to finish was applied. Complex interpolated movement is transform into simple two-dimension curved movement to shorten machine time and increase of efficiency in the way. In addition, machined surface with burnishing effect, high precision and high surface quality is obtained.

Sign in / Sign up

Export Citation Format

Share Document