scholarly journals Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

Studies on Cutting Forces of High Volume Fraction SiCp/Al Composites with Ultrasonic Vibration High Speed Milling

2011 ◽  
Vol 295-297 ◽  
pp. 785-788 ◽  
Author(s):  
Dao Hui Xiang ◽  
Guang Xi Yue ◽  
Xin Tao Zhi ◽  
Hai Tao Liu ◽  
Bo Zhao
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
Matrix Composites ◽  
Machining Performance ◽  
High Speed Milling ◽  
Hard Cutting

The orthogonal method was used for analyzing the machining performance of high volume fraction SiCp/Al metal matrix composites (SiCp/Al MMCs) during high speed milling and ultrasonic high speed milling in this paper. The influence of cutting speed, feed rate and cutting depth on 3-directional forces were investigated. The results show that the cutting forces are decreased due to the cutting mechanism of SiCp/Al MMCs is changed from brittle cutting to ductile cutting during ultrasonic high speed milling. In addition, the chips exist in forms of C-type chips because of increasing rake angles. Ultrasonic high-speed milling is a more highly effective hard cutting way compared with high speed milling.

Study on Finite Element Simulation of the Influence of Cutting Speed on Chip Formation of SiCpAl Composites in High Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 290-295
Author(s):  
Chuang Liu ◽  
Shu Tao Huang ◽  
Ke Ru Jiao ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
High Speed Milling ◽  
Finite Element Software ◽  
High Efficient

Application prospect of the high volume fraction SiCp/Al composites becomes increasingly widespread, the study of cutting mechanism is important for achieving its high efficient and precision machining. In this paper, a three-dimensional beveled simulation model of high volume fraction SiCp/Al composites on high-speed milling is established by finite element software ABAQUS, the constitutive on model material, the tool-chip contact and the chip separation model is elected reasonably.The paper analyzes the effect of cutting speed on the chip formation and the stress distribution of the material. The results shows that: with the increasing of cutting speed, the chip is easily broken, cutting speed have little impact on the maximum stress of the material.

Study on Milling Force of High Volume Fraction SiCp/Al Composites with Ultrasonic Longitudinal and Torsional Vibration High Speed Milling

2014 ◽  
Vol 910 ◽  
pp. 114-117 ◽  
Author(s):  
Dao Hui Xiang ◽  
Guang Bin Yang ◽  
Song Liang ◽  
Yan Feng Wang ◽  
Qiang Qin
Keyword(s):  
Torsional Vibration ◽  
High Speed ◽  
Volume Fraction ◽  
Fold Increase ◽  
High Volume ◽  
High Volume Fraction ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Method ◽  
Milling Forces

High volume fraction SiCp/Al composites were milled in ultrasonic longitudinal and torsional vibration high speed milling and high speed milling in this experiment, study on effects of different milling parameters (milling depth ap, feed engagement fz, the milling speed vz) on milling force. The results shows that in the same cutting parameters ,the three milling force of ultrasonic longitudinal and torsional vibration high speed milling are smaller than that of high speed milling, and milling forces of two milling method increase with the add of the milling depth and feed engagement ,but they aren't fold increase. Milling forces of two milling method decrease with the add of the the minlling speed,and the changes become gently when the the minlling speed run up to 170m/min, with the further increase of the milling speed,ultrasonic vibration high speed milling will translate to high speed milling, this is because the torsional vibration is submerged.

scholarly journals Large-scale synthesis of polyhedral Ag nanoparticles for printed electronics

RSC Advances ◽  
2017 ◽  
Vol 7 (86) ◽  
pp. 54326-54331 ◽  
Author(s):  
Shlomi Polani ◽  
Semyon Melamed ◽  
Luba Burlaka ◽  
Fernando De La Vega ◽  
David Zitoun
Keyword(s):  
Ag Nanoparticles ◽  
Large Scale ◽  
Printed Electronics ◽  
Volume Fraction ◽  
High Volume ◽  
High Volume Fraction ◽  
Electrically Conductive ◽  
Large Scale Synthesis

The large-scale synthesis of polyhedral Ag nanoparticles (NPs) described here follows a mediated-particle mechanism and the formulation of NPs in high volume fraction ink easily forms highly electrically conductive lines for printed electronics.

Simulation of Tool Wear in Prestressed Cutting Superalloys

2016 ◽  
Vol 836-837 ◽  
pp. 402-407
Author(s):  
Rui Tao Peng ◽  
Jing Li ◽  
Xin Zi Tang ◽  
Zhuan Zhou
Keyword(s):  
Finite Element ◽  
Wear Rate ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Wear Model ◽  
Element Analysis ◽  
Wear Calculation

In high speed machining superalloys processes, tool wear is strongly influenced by the cutting temperature and contact stresses. Finite element analysis of machining can be used as a supplementary to the physical experiment, this paper provides investigations in 2D and 3D finite element modeling and simulation of prestressed cutting for GH4169 superalloy, a tool wear model for the specified tool and workpiece pair is developed based on the Usui's wear model, furthermore, tool temperature, wear rate and nodal displacement on the face of tool in prestressed cutting of superalloy is analyzed under various prestress condition and cutting parameters, and Python language is adopted to modify the Abaqus code used to allow tool wear calculation and tool geometry updating. The results of the simulation indicate that the tool wear rate increases with the increase of cutting time, and the influence of the prestress to tool wear in prestressed cutting process of shaft part is unremarkable.

Study on Tool Wear of High Volume Fraction SiCp/Al Composites with Ultrasonic Vibration High Speed Milling

2012 ◽  
Vol 252 ◽  
pp. 198-201 ◽  
Author(s):  
Dao Hui Xiang ◽  
Hai Tao Liu ◽  
Xiao Jiang ◽  
Song Liang ◽  
Guang Bin Yang
Keyword(s):  
Ultrasonic Vibration ◽  
High Speed ◽  
Cutting Tool ◽  
Volume Fraction ◽  
High Volume ◽  
High Volume Fraction ◽  
Milling Tool ◽  
The Relationship ◽  
Milling Tools ◽  
Vibration Milling

Abstract: High volume fraction SiCp/Al composites were milled in ultrasonic longitudinal high frequency vibration milling and conventional milling in this experiment. Meanwhile, the form of wear and wear mechanism of PCD milling tools were investigated. In addition, the relationship between the maximum wear of PCD milling tool and the length of milling were obtained. The results show that it is mainly flank wear of PCD cutting tool under the same milling parameters, which are caused due to hard points wear and thermal and chemical wear. Furthermore, the wear of PCD cutting tool by the ultrasonic vibration milling is smaller than that obtained by the conventional milling.

FEM Investigation of Machinability Properties of SiCp/Al Composites

2010 ◽  
Vol 455 ◽  
pp. 220-225
Author(s):  
Li Zhou ◽  
Shu Tao Huang
Keyword(s):  
Cutting Force ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
High Volume ◽  
Shear Angle ◽  
Workpiece Material ◽  
Element Analysis ◽  
Dynamic Finite Element ◽  
Dynamic Finite Element Analysis

In this paper, a transient dynamic finite-element analysis was carried out to investigate the effects of the cutting speed on cutting force, cutting temperature, and the chip-shear angle. The workpiece material is SiCp/Al composites with lager particle and high volume fraction. The results show that the cutting force decreased, while the cutting temperature and chip-shear angle increased evidently with increasing of cutting speed. The results obtained from this study can predict the behaviors of machining SiCp/Al composites very well and the variation trend is agree well with that of the experiments.

Experimental Study on Precision Milling of High Volume Fraction SiCP/Al Composites with PCD End Mills

2013 ◽  
Vol 770 ◽  
pp. 100-105 ◽  
Author(s):  
Qi Wu ◽  
Liang Li ◽  
Rong Bian ◽  
Zhen Yu Shi ◽  
Ning He
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Tool Wear ◽  
Volume Fraction ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
Experimental Result ◽  
Machined Surface ◽  
End Mills

This paper presents an experimental study on precision milling of high volume fraction SiCP/Al composites with single flute polycrystalline diamond (PCD) end mills. Based on a series of tests, the present study is focused on surface roughness of machined surface and tool wear of single flute PCD end mills. The effect of cutting parameters such as feed per tooth (fz) and depth of cut (ap) on the machined surface roughness (Ra) was investigated. Tool wear was also inspected and analyzed by Scanning Electron Microscope (SEM). According to the results of experiment, there is a layer of aluminum covered on the machined surface. This layer of aluminum can improve the machined surface quality. Through the comparsion of surface roughness in different cutting parameters, it can decrease surface roughness (Ra) by means of using very small cutting parameters. Flank wear and chipping are two main kinds of tool wear. The observed wear mechanism of PCD tools is abrasive wear and adhesive wear. The purpose of this study is to provide an experimental result for further investigation on milling of high volume fraction SiCP/Al composites.

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