Study on the Green Processing of Impeller

2010 ◽  
Vol 136 ◽  
pp. 148-152
Author(s):  
Ming Jun Feng ◽  
C.T. Sun ◽  
Xue Feng Wang ◽  
H.J. Sun
Keyword(s):  
High Speed ◽  
Production Cost ◽  
Development Trend ◽  
Virtual Manufacturing ◽  
Machining Process ◽  
High Speed Machining ◽  
Good Surface ◽  
Green Processing ◽  
Compressor Impeller ◽  
Good Surface Roughness

According to the characteristics and cutting requirements of the compressor impeller, such as low rigidity, easy to produce deformation and vibration in machining process, the high speed machining technology was adopted to reduce time, the virtual manufacturing technology was used to solve processing problems in computer before the trial machining and improved programming speed and other key supporting technologies were adopted. The study shows that this green processing of impeller had high machining efficiency, good surface roughness and product quality, low production cost and light environmental pollution. It accords with modern green machining development trend.

Application of Virtual Manufacturing to Impeller Five-Axis High Speed Machining

2009 ◽  
Vol 407-408 ◽  
pp. 239-242
Author(s):  
Xue Hui Wang ◽  
Ming Jun Feng ◽  
Shi Cheng Liu
Keyword(s):  
High Speed ◽  
Virtual Manufacturing ◽  
Machining Process ◽  
High Speed Machining ◽  
Interference Phenomenon ◽  
The Real ◽  
Nc Program ◽  
Complicated Process ◽  
Trial Test ◽  
Five Axis

For taking advantage of high speed machining(HSM) in complex curved surfaces as impeller, the virtual manufacturing technology is adopted before the real machining, which can eliminate tool collision interference phenomenon of the trial cutting, avoid complicated process of trial test , forecast machining results efficiently. The simulation tests were proceeded to the each impeller procedure NC program by using the VERICUT virtual manufacturing soft to modeling five-axis machine tool HSM600U, and the result compared with the real machining is identical with one other. So it is tested that applying this technology can forecast the machining process truly.

Numerical Simulation of Cutting Force in High Speed Machining of Inconel 718

2020 ◽  
Vol 856 ◽  
pp. 43-49
Author(s):  
Santosh Kumar Tamang ◽  
Nabam Teyi ◽  
Rinchin Tashi Tsumkhapa
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Experimental Result ◽  
Work Piece ◽  
High Speed Machining ◽  
Numerical Result ◽  
3D Software

Machining is one of the major manufacturing processes that converts a raw work piece of arbitrary size into a finished product of definite shape of predetermined size by suitably controlling the relative motion between the tool and the work. Lately, machining process is shifting towards high speed machining (HSM) from conventional machining to improve and efficiently increase production, and towards dry machining from excessive coolant used wet machining to improve economy of production. And the tools used are mostly hardened alloys to facilitate HSM. The work piece materials are continually improving their properties by emergence and development of newer and high resistive super alloys (HRSA). In this paper an attempt has been made to validate an experimental result of cutting force obtained by performing HSM on an HRSA Inconel 718, by comparing it with the numerical result obtained by simulating the same setting using DEFORM 3D software. Based on the comparison it is found that the simulated results exhibit close proximity with the experimental results validating the experimental results and the effectiveness of the software.

scholarly journals Impact of Cutting Environments on Sustainable Machining of H13 Tool Steel Alloy

2020 ◽  
Vol 5 (2) ◽  
Author(s):  
Vincent A Balogun ◽  
Isuamfon F Edem ◽  
Etimbuk B Bassey
Keyword(s):  
Tool Life ◽  
Tool Steel ◽  
High Speed ◽  
Machining Process ◽  
Steel Alloy ◽  
High Speed Machining ◽  
Sustainable Machining ◽  
H13 Tool Steel ◽  
Green Machining ◽  
The Impact

The use of electrical energy and coolants/lubricants has been widely reported in mechanical machining. However, increased research and process innovation in high speed machining has brought about optimised manufacturing cycle times. This has promoted dry machining and the use of minimum quantity lubrication (MQL). This work understudies the impact of different cutting environments in machining H13 tool steel alloys at transition speed regime with emphasis on sustainable machining of the alloy. To achieve this, end milling tests were performed on AISI H13 steel alloy (192 BHN) on a MIKRON HSM 400 high speed machining centre using milling inserts. After each cutting pass, the milling insert was removed for tool wear measurement on the digital microscope. The electrical power consumed was measured with the Fluke 435 power clamp meter mounted on the three phase cable at the back of the machine. It was discovered that MQL has a promising advantage in terms of tool life with 25 minutes of machining, net power requirement of 10% when compared to dry cutting, and environmental benefits when machining H13 tool steel alloy. This work is fundamentally important in assessing the environmental credentials and resource efficiency regime for green machining of H13 tool steel alloysKeywords— H13 tool steel, green machining, process optimization, tool life, cutting environments, energy consumption 

Stress Triaxiality in Chip Segmentation During High Speed Machining of Titanium Alloy

2014 ◽  
Author(s):  
Xueping Zhang ◽  
Rajiv Shivpuri ◽  
Anil K. Srivastava
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Shear Bands ◽  
Stress Triaxiality ◽  
Machining Process ◽  
High Speed Machining ◽  
Hopkinson Pressure Bar ◽  
Static Tests ◽  
Pressure Stress

Beside strain intensity, stress triaxiality (pressure-stress states) is the most important factor to control initiation of ductile fracture in chip segmentation through affecting the loading capacity and strain to failure. The effect of stress triaxiality on failure strain is usually assessed by dynamic Split Hopkinson Pressure Bar (SHPB) or quasi-static tests of tension, compression, torsion, and shear. However, the stress triaxialities produced by these tests are considerably different from those in high speed machining of titanium alloys where adiabatic shear bands (ASB) are associated with much higher strains, stresses and temperatures. This aspect of shear localization and fracture are poorly understood in previous research. This paper aims to demonstrate the role of stress triaxiality in chip segmentation during machining titanium alloy using finite element method. This research promotes a fundamental understanding of thermo-mechanics of the high-speed machining process, and provides a logical insight into the fracture mechanism in discontinuous chips.

Reduction of Vibrations due to Unbalance with Anti-Vibration Clearance Angle in High Speed Milling

2016 ◽  
Vol 836-837 ◽  
pp. 161-167
Author(s):  
Anna Thouvenin ◽  
Xin Li ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Machining Process ◽  
High Speed Machining ◽  
Machining Processes ◽  
High Speed Milling ◽  
Clearance Angle ◽  
Fast Solution ◽  
Considerable Problem

High speed milling is one of the most commonly used machining processes in many fields of the industry. It is regarded as a simple and fast solution to achieve a high material removal rate, which allows an important production of parts. Unbalance is a problem in any machining process but becomes a considerable problem when reaching high speed machining. The vibrations due to an unbalanced tool or tool holder can result in a poor surface quality and a damaged tool. The damping of the vibrations can be achieved with a specially designed tool showing an anti-vibration clearance angle. This paper shows the influence of the anti-vibration clearance angle by a computational model and a set of experiments to see if it can reduce or suppress the vibrations due to unbalance in high speed milling.

The role of material model in the finite element simulation of high-speed machining of Ti6Al4V

2016 ◽  
Vol 230 (17) ◽  
pp. 2959-2967 ◽  
Author(s):  
Chong-Yang Gao ◽  
Liang-Chi Zhang ◽  
Peng-Hui Liu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
High Speed ◽  
Material Model ◽  
Machining Process ◽  
High Speed Machining ◽  
Serrated Chip ◽  
Finite Element Program ◽  
Element Simulation ◽  
Improved Model

This paper provides a comprehensive assessment on some commonly used thermo-viscoplastic constitutive models of metallic materials during severe plastic deformation at high-strain rates. An hcp model previously established by us was improved in this paper to enhance its predictability by incorporating the key saturation characteristic of strain hardening. A compensation-based stress-updating algorithm was also developed to introduce the new hcp model into a finite element program. The improved model with the developed algorithm was then applied in finite element simulation to investigate the high-speed machining of Ti6Al4V. It was found that by using different material models, the simulated results of cutting forces, serrated chip morphologies, and residual stresses can be different too and that the improved model proposed in this paper can be applied to simulate the titanium alloy machining process more reliably due to its physical basis when compared with some other empirical Johnson–Cook models.

Microhardness Prediction Based on a Microstructure-Sensitive Flow Stress Model During High Speed Machining Ti-6Al-4V

2018 ◽  
Vol 140 (9) ◽  
Author(s):  
Qingqing Wang ◽  
Zhanqiang Liu
Keyword(s):  
Flow Stress ◽  
Grain Refinement ◽  
High Speed ◽  
Direct Consequence ◽  
Deformation Twinning ◽  
Machining Process ◽  
High Speed Machining ◽  
Stress Model ◽  
Machined Surface ◽  
Flow Stress Model

Exploring the hardening mechanisms during high speed machining (HSM) is an effective approach to improve the fatigue strength and the wear resistance of machined surface and to control the fragmentation of chips in a certain range of hardness. In this paper, the microhardness variation is explored from the perspective of microstructural evolutions, as a direct consequence of the severe deformation during HSM Ti-6Al-4V alloy. A microstructure-sensitive flow stress model coupled the phenomena of grain refinement, deformation twinning, and phase transformations is first proposed. Then the microstructure-sensitive flow stress model is implemented into the cutting simulation model via a user-defined subroutine to analyze the flow stress variation induced by the microstructure evolutions during HSM Ti-6Al-4V. Finally, the relationship between the microhardness and flow stress is developed and modified based on the classical theory that the hardness is directly proportional to the flow stress. The study shows that the deformation twinning (generated at higher cutting speeds) plays a more important role in the hardening of Ti-6Al-4V compared with the grain refinement and phase transformation. The predicted microhardness distributions align well with the measured values. It provides a novel thinking that it is plausible to obtain a high microhardness material via controlling the microstructure alterations during machining process.

Burr Formation and Surface Quality in High Speed Micromilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Author(s):  
Vivek Bajpai ◽  
Ajay K. Kushwaha ◽  
Ramesh K. Singh
Keyword(s):  
High Speed ◽  
Removal Rate ◽  
Weight Ratio ◽  
Machining Process ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Good Surface ◽  
Mechanical Machining ◽  
Tool Diameter

Titanium and Ti alloys are popular materials used in aviation and biomedical field due to their excellent strength-to-weight ratio and corrosion resistance properties. Micromilling is a common mechanical machining process used in the production of microscale features. The micro-tool has very low stiffness and even small forces can lead to catastrophic tool failure. High speed micromachining can be used to address the issue because of lower chip loads at higher rotational speeds. Consequently, high speed micromilling can be used for micromachining of hard metals/alloys which are difficult to accomplish at lower speeds. Nowadays high speed micromilling is gaining popularity due to its high material removal rate and good surface finish. In many cases, the machined product does not need an additional finishing process. However, the burr formation in the mechanical machining process is the most important problem which becomes more critical for a microscale feature. Removal of micro-size burr is much more difficult than its macro counterpart. The current work is focused on the characterization of the burr formation in high speed micromilling. Influence of various process parameters, viz., spindle speed, feed rate, depth of cut, tool diameter and number of flutes of the micromilling tool has been analyzed on the burr size and on the quality of the machined surface via measuring the surface roughness.

Finite Element Simulation of High Speed Machining of Ti6Al4V Alloy and the Corresponding Experimental Study

2016 ◽  
Vol 836-837 ◽  
pp. 444-451 ◽  
Author(s):  
Long Hui Meng
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Finite Element Simulation ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
High Speed Machining ◽  
Hopkinson Pressure Bar ◽  
Element Simulation

Finite element simulation of high speed machining of Ti6Al4V alloy was carried out based on the software of Abaqus. The Johnson-Cook constitutive model was chosen for the material of Ti6Al4V, the parameters of the model were obtained through the SHPB (Split Hopkinson Pressure Bar) experiment. The similarity of the chips obtained from the simulation and that obtained from the experiment indicated that the parameters of the Johnson-Cook constitutive model for Ti6Al4V alloy were reliable. Different cutting parameters and different tool geometric parameters were used in the simulations to find out their effects to the simulation results. Also a comparison was made between the results got form the simulations results and the experimental results, a good agreement between them indicated that the finite element simulation of high speed machining of Ti6Al4V is reliable, so it can be concluded that the finite element simulations of high speed machining can be widely used in practice to study the more about the machining process and reduce the experimental expenses.

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