scholarly journals Influence of Lubricant Environment on Machined Surface Quality in Single-Point Diamond Turning of Ferrous Metal

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1110
Author(s):  
Menghua Zhou ◽  
Jianpeng Wang ◽  
Guoqing Zhang
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
Surface Quality ◽  
Single Point ◽  
Ferrous Metal ◽  
Minimum Quantity Lubrication ◽  
Diamond Turning ◽  
Machined Surface ◽  
Hard Particles ◽  
Machined Surface Quality

In the field of single-point diamond turning (SPDT), machining ferrous metal is an important research topic with promising application. For SPDT of ferrous metal, the influence of lubricant on the workpiece surface morphology remains to be studied. In this study, three lubricant machining environments were selected to carry out specific control experiments. The machined surface morphology and cutting force in different lubricant machining environments were analyzed. The experiment results showed that the lubricant environment will have significant impacts on the quality of the machined surface morphology of ferrous metal. In the environment of minimum quantity lubrication machining (MQLM-oil), better machined surface quality can be obtained than that in ordinary dry machining (ODM) and high-pressure gas machining (HGM). Furthermore, the cutting force captured in the ODM and HGM environment increased with the increase of the cutting depth, while the cutting force in the MQLM-oil environment remained almost unchanged. That indicates MQLM-oil can suppress the formation of hard particles to improve the machining quality.

Optical Effects of Surface Finish by Ultraprecision Single Point Diamond Machining

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lei Li ◽  
Stuart A. Collins ◽  
Allen Y. Yi
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Optical Diffraction ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Marks ◽  
Tool Mark ◽  
Machined Surface Quality ◽  
Machined Surfaces

The single point diamond turning process has been used extensively for direct optical surface fabrication. However, the diamond machined surfaces have characteristic periodic tool marks, which contribute to reduced optical performance such as scattering and distortion. In this paper, studies of the characteristics of diamond machined surface and scattering from the diamond machined surfaces are presented. Four different parameters, the first order optical diffraction, the zero order reflection, the surface roughness, and the residual tool mark depth, are used as indicators for the machined surface quality. Four sets of tests are presented showing the relationship between machined surface quality and machining conditions such as spindle speed, feedrate, and machining process. Finally, an empirical model is given based on the measurements.

scholarly journals The Comparative Study on Cutting Performance of Different-Structure Milling Cutters in Machining CFRP

2018 ◽  
Vol 8 (8) ◽  
pp. 1353
Author(s):  
Tao Chen ◽  
Fei Gao ◽  
Suyan Li ◽  
Xianli Liu
Keyword(s):  
Carbon Fiber ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Edge ◽  
Cutting Performance ◽  
Machining Process ◽  
Carbon Fiber Composites ◽  
Machined Surface ◽  
Milling Cutter ◽  
Machined Surface Quality

Carbon fiber reinforced plastic (CFRP) is typically hard to process, because it is easy for it to generate processing damage such as burrs, tears, delamination, and so on in the machining process. Consequently, this restricts its wide spread application. This paper conducted a comparative experiment on the cutting performance of the two different-structure milling cutters, with a helical staggered edge and a rhombic edge, in milling carbon fiber composites; analyzed the wear morphologies of the two cutting tools; and thus acquired the effect of the tool structure on the machined surface quality and cutting force. The results indicated that in the whole cutting, the rhombic milling cutter with a segmented cutting edge showed better wear resistance and a more stable machined surface quality. It was not until a large area of coating shedding occurred, along with chip clogging, that the surface quality decreased significantly. At the stage of coating wear, the helical staggered milling cutter with an alternately arranged continuous cutting edge showed better machined surface quality, but when the coating fell off, its machined surface quality began to reveal damage such as groove, tear, and fiber pullout. Meanwhile, burrs occurred at the edge and the cutting force obviously increased. By contrast, for the rhombic milling cutter, both the surface roughness and cutting force increased relatively slowly.

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

Influence of Fiber Orientation on Machined Surface Quality in Milling of Unidirectional CFRP Laminates

2016 ◽  
Vol 1136 ◽  
pp. 137-142 ◽  
Author(s):  
Chang Ying Wang ◽  
Liang Wen ◽  
Cheng Dong Wang ◽  
Hong Zhou Zhang ◽  
Qing Long An ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Surface Quality ◽  
Fiber Orientation ◽  
Orientation Angle ◽  
Machined Surface ◽  
Cfrp Laminates ◽  
Pull Out ◽  
Machined Surface Quality ◽  
Fiber Orientation Angle

Machined surface quality is the deciding factor when evaluating the machinability of CFRP. This present work concerns the influence of fiber orientation on the machined surface quality of the machined surface in terms of surface morphology and surface roughness during milling of unidirectional T800/X850 CFRP laminates. Four group milling tests are conducted under the fiber orientation angle of 0°, 45°, 90° and 135°, respectively. For the fiber orientation angle of 0°, the machined defects are mainly fiber pull-out and fiber brittle fracture owing to interfacial debonding between the fibers and matrix resin. For the fiber orientation angle of 45°, the machined defects are mainly resin cavities and the surface morphology is rough and presents wavy fractures. For the fiber orientation angle of 90°, smooth or neat surface is observed except for the surface as the cutting tool cutting in the workpiece on which severe cracks are observed. For the fiber orientation angle of 135°, the surface is smooth with less fibers pull-out. Evaluation profile and surface roughness of the machined surfaces were measured as well. Dramatically fluctuate of the evaluation profile is observed for the fiber orientation angle of 45° with a high surface roughness Ra. Verification tests were also conducted on the multidirectional CFRP (cross-ply) laminates. It is indicated that the presence of the fiber orientation angle of 45° is the main factor leading to the decline of the machined surface quality.

Study of High Efficiency in Green Cutting Nickel-Based Superalloy GH4169

2010 ◽  
Vol 33 ◽  
pp. 555-559
Author(s):  
Rong Di Han ◽  
Hui Wang ◽  
Y. Zhang ◽  
Q.W. Yao
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dry Cutting ◽  
Machined Surface ◽  
Nickel Based Superalloy ◽  
Machined Surface Quality

The machinability of nickel-based superalloy GH4169 is very poor, the traditional machining of GH4169 using the cutting fluids with the active additives causes environmental and health problems, which is out of the request of the sustainable development strategy. In this paper a new green cutting technology with overheated water vapor as coolants and lubricants was proposed to achieve the aim of green cutting and high productivity. Cutting experiments and tool wear tests using carbide tool YG6 under dry cutting, emulsion and water vapor were performed. The cutting force, cutting temperature, machined surface quality and tool life were investigated; the curve of flank tool wear and relation between tool life and cutting velocity was carried out. The results of experiments indicated that during water vapor condition, the cutting force and cutting temperature was reduced, the machined surface roughness was improved, and the tool life was longed, respectively, and the higher velocity was taken during the some tool wear condition compared to dry cutting. The research results show that green cutting was achieved associated with overheated water vapor cooling and lubricating, at he same time the machined surface quality and production efficiency was increased.

Study on the Cutting Force and Machined Surface Quality of Milling AFRP

2016 ◽  
Vol 836-837 ◽  
pp. 155-160 ◽  
Author(s):  
Si Qi Liu ◽  
Yan Chen ◽  
Yu Can Fu ◽  
An Dong Hu
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Helix Angle ◽  
End Mill ◽  
Machined Surface ◽  
Reinforced Plastics ◽  
Machined Surface Quality

AFRP(Aramid Fiber Reinforced Plastics) is widely used in the aerospace and automotive while there are many problems in machining AFRP such as furry, delamination, burns and so on. Milling experiments of AFRP have been conducted to study the influence of different helix angle (0°, 30°, 60°) and cutting tools (traditional end mill, multiple flute end mill and compression end mill) on cutting force and machined surface quality. The results indicated that the cutting force has been reduced and the surface quality has been improved with the increase of helix angle. The cutting tool structure can make greater influence on machined surface quality than the cutting parameters. A cutting tool with the structure of multiple flute or herringbone cutting edge could reduce the axial cutting force. However the cutting force is too small to cut off fibers when using a multiple flute end mill. A good processing surface can be achieved while cutting with a compression end mill or a tool with big helix angle.

scholarly journals Generation Mechanism and Dual Dynamic Simulations of Surface Patterns in Single-Point Diamond Turning of Single-Crystal Copper

2021 ◽  
Author(s):  
Jie Xiong ◽  
Yanbing Chen ◽  
Yuqi Dai ◽  
Guoqing Zhang ◽  
Jiaqi Ran ◽  
...  
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Generation Mechanism ◽  
Machined Surface ◽  
Single Crystal Copper ◽  
Angle Change ◽  
Fundamental Understanding ◽  
Shaped Pattern ◽  
Cutting Direction

Abstract Single-crystal copper (Cu), whose atom arrangement is in the same direction and has no grain boundary, is widely used in defense technology, civil electronics and network communication. As a diamond turnable material, fan-shaped patterns appear on the machined surface, which affects the machined surface quality and the optical function it carries. Previous studies on the surface generation mechanism in single-point diamond turning (SPDT) of Cu were limited to experimental analysis, while there is a lack of fundamental understanding of the fan-shaped pattern generation mechanism and suppression method. In the present study, the different fan-shaped patterns, surface quality, cutting force and chip morphology of the typical crystal planes (100), (110) and (111) planes of Cu were studied by both theoretical and experimental analyses. A molecular dynamics (MD) simulation was conducted to present the fundamental generation mechanism of the fan-shaped patterns from atom arrangement directions and its angle change with the main cutting direction, while a cutting dynamics model was established to simulate the generation of fan-shaped patterns on the machined surface. Based on theoretical and experimental analysis, it was found that the atom density arrangement directions of Cu and its angle change with the main cutting direction of SPDT caused fluctuations in the friction coefficient, which further caused the vibration of the cutting system and generated the fan-shaped patterns. The SPDT of crystal planes (100) can achieve the best surface quality. The present research provides a fundamental understanding of fan-shaped pattern formation on the machined surface, and provides an instruction for machining Cu to obtain better surface quality.

Machining Induced Defects and the Influence Factors when Diamond Turning of SiCp/Al Composites

2007 ◽  
Vol 10-12 ◽  
pp. 626-630 ◽  
Author(s):  
Y.F. Ge ◽  
Jiu Hua Xu ◽  
Hui Yang ◽  
S.B. Luo ◽  
Yu Can Fu
Keyword(s):  
Surface Quality ◽  
Volume Fraction ◽  
Single Point ◽  
Influence Factors ◽  
Polycrystalline Diamond ◽  
High Volume ◽  
Diamond Turning ◽  
Dry Cutting ◽  
Machined Surface ◽  
Pcd Tools

Ultra-precision turning tests on SiCp/2024Al and SiCp/ZL101A composites were carried out to investigate the surface quality using single point diamond tools (SPDT) and polycrystalline diamond (PCD) cutters. Examined by SEM, the machined surfaces took on many defects such as pits, voids, microcracks, grooves, protuberances, matrix tearing and so on. The results showed that surface quality debased with increasing feed rate or using of high volume fraction materials. Dry cutting would deteriorate the surface finish. It was also pointed out that SPDT outperformed PCD tools although they produced the same surface roughness Ra. Microhardness measuring showed that the deformation layer was extended to 8–16μm below the machined surface.

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