Research on Cutting Cast Super Alloy K24 with Milling and Abrasive Water Jet Methods

2011 ◽  
Vol 697-698 ◽  
pp. 157-160
Author(s):  
Yi Wan ◽  
Zhan Qiang Liu ◽  
Hong Tao Zhu ◽  
Xing Ai
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
High Efficiency ◽  
Abrasive Waterjet ◽  
Abrasive Water Jet ◽  
Good Surface ◽  
Low Efficiency ◽  
Good Surface Roughness ◽  
Super Alloy ◽  
Tool Cost

A difficult-to-machining material, cast supper alloy K24 has been cut with two different methods, milling and abrasive waterjet (AWJ). It is shown that milling is characterized by high tool cost, low efficiency, and good surface roughness while abrasive waterjet brings high efficiency and worse surface quality. The results have proven that the combination use of AWJ and milling is an efficient way in cutting K24.

Polishing Experiment Study of the Elastic Coated Abrasives

2014 ◽  
Vol 941-944 ◽  
pp. 1981-1984
Author(s):  
Gui Lian Wang ◽  
Hai Bo Zhou ◽  
Shu Li Guo ◽  
De Chen Huang ◽  
Ren Bao Jiao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Efficiency ◽  
Future Research ◽  
Workpiece Material ◽  
Good Surface ◽  
Aisi 1045 Steel ◽  
Good Surface Roughness ◽  
1045 Steel ◽  
Polishing Efficiency ◽  
Coated Abrasives

A kind of elastic coated abrasives used for polishing large mould surface, such as automobile panel mould, is investigated in this research. Many polishing experiments were finished by using elastic coated abrasives in order to study the effects of grit and workpiece material on surface roughness and machining efficiency. It is concluded that surface roughness is minimum and polishing efficiency is the highest when using 120# abrasives at the same condition, surface roughness is the lowest and polishing efficiency is the highest for AISI 1045 steel in three materials. The difficulty of material removal is different if the textures prior to polishing are different in workpiece surface. Surface texture prior to polishing has effects on surface roughness and polishing efficiency. The research results provide foundation for process planning to achieve good surface roughness and high efficiency in the future research.

Study on Semi-Fixed Abrasive Lapping of Ultra-Thin Silver Electrode Layer

2009 ◽  
Vol 69-70 ◽  
pp. 225-228
Author(s):  
Xun Lv ◽  
Ju Long Yuan
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
High Efficiency ◽  
Processing Parameters ◽  
Silver Electrode ◽  
Processing Load ◽  
Electrode Layer ◽  
Good Surface ◽  
Good Surface Quality ◽  
Ultra Precision

Silver electrode layer of piezoelectric ceramic transducer requires good surface quality and high efficiency. Efficiency of traditional lapping and polishing is very low. Ultra-precision grinding technology is also unsuitable for the thickness of workpiece is extremely thin. Semi bonded abrasive lapping is a new ultra-precision processing method. The new ultra-precise method can achieve good surface quality in short time, and removal stock of workpiece is small. In order to research the optimal technology of semi bonded abrasive lapping about silver electrode layer, this paper research several major processing parameters by experiments. The results show that appropriate processing load can obtain better surface roughness of silver electrode layer，and surface roughness of silver electrode layer has little change with different processing speed. By using ultra-fine semi bonded abrasive plate, 94.08KPa processing load and 40 rpm polishing speed, after 30 minutes, surface roughness of silver electrode layer is 11nm, and removal stock is 11.5μm.

Experimental Research of the Elastic Abrasive Tool Used for Finishing Mould Surface

2011 ◽  
Vol 101-102 ◽  
pp. 998-1001
Author(s):  
Gui Lian Wang ◽  
Yi Qiang Wang ◽  
Hai Bo Zhou ◽  
Bing Bing Yan
Keyword(s):  
Surface Roughness ◽  
High Efficiency ◽  
Free Form ◽  
Abrasive Tool ◽  
Good Surface ◽  
Mould Surface ◽  
Polishing Force ◽  
Polishing Path ◽  
Good Surface Roughness ◽  
Polishing Pressure

A compliant abrasive tool is investigated in this paper. By the polishing experiment of this abrasive tool, the technique of polishing the large mould free-form surface is acquired. The polishing experiments about the elastic abrasive tool are carried out, which indicates that the abrasive tool has the advantages of the high efficiency, the elasticity and compliant performance. The relation of the deflection and polishing force is investigated and it is concluded that they is approximately linearity. The effect of polishing pressure on the surface roughness is researched by experiment. Polishing quality for the edge of abrasive tool was investigated and presented. These experiment results provide significant foundation for planning polishing path and controlling process parameters to achieve good surface roughness and high efficiency in the next research.

A New Method of Processing High-Precision Micro-Hole with the Femtosecond Laser

2012 ◽  
Vol 268-270 ◽  
pp. 382-386
Author(s):  
Xiao Jun Yang ◽  
Ming Li ◽  
Li Wang ◽  
Hua Long Zhao ◽  
Guang Hua Chen
Keyword(s):  
Surface Roughness ◽  
Femtosecond Laser ◽  
High Precision ◽  
High Efficiency ◽  
Surface Profile ◽  
Good Surface ◽  
Industry Applications ◽  
Micro Hole ◽  
Good Surface Roughness ◽  
Application Requirements

Based on the femtosecond laser processing technology and PZT driving scanning technology,high-precision micro- manufacturing technology is developed. By adjusting the laser parameters and scanning parameters to get micro-hole machining on the flat or curved surface. Hole’s size and surface morphology is observed by using phase contrast microscopy and scanning electron microscopy observations, and the surface roughness is analyzed by the surface profile instrument. The feasibility of diesel injector nozzle processing is verified in practical industry applications. The results show that this method of making micro hole has significant advantages, such as high precision, good consistency, without burrs, good surface roughness and high efficiency. These characteristics can meet the practical application requirements and can be used in various industrial fields.

Evaluation of Surface Integrity in Electrochemical Micromachining of A286 Super alloy

2021 ◽  
Author(s):  
Rajkeerthi E ◽  
Hariharan P
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Integrity ◽  
Research Work ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Dissolution Mechanism ◽  
Machined Surface ◽  
Micro Holes ◽  
Super Alloy

Abstract Surface integrity of micro components is a major concern particularly in manufacturing industries as most geometry of the products must meet out necessary surface quality requirements. Advanced machining process like electrochemical micro machining possess the capabilities to machine micro parts with best surface properties exempting them from secondary operations. In this research work, different electrolytes have been employed for producing micro holes in A286 super alloy material to achieve the best surface quality and the measurement of surface roughness and surface integrity to evaluate the machined surface is carried out. The machined micro hole provides detailed information on the geometrical features. A study of parametric analysis meant for controlling surface roughness and improvement of surface integrity has been made to find out the suitable parameters for machining. The suitability of various electrolytes with their dissolution mechanism and the influence of various electrolytes have been thoroughly studied. Among the utilized electrolytes, EG + NaNO3 electrolyte provided the best results in terms of overcut and average surface roughness.

scholarly journals An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

2021 ◽  
Author(s):  
Sonia Ezeddini ◽  
Wajdi Rajhi ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar ◽  
Sahbi Ben Salem
Keyword(s):  
Surface Roughness ◽  
Pulse Duration ◽  
Surface Integrity ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Good Surface ◽  
Pulse On Time ◽  
Super Alloy

Abstract Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

Surface Quality Prediction in Case of Steep Free Form Surface Milling

2016 ◽  
Vol 686 ◽  
pp. 119-124 ◽  
Author(s):  
Balázs Mikó
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Path ◽  
Complex Geometry ◽  
Cutting Parameters ◽  
Free Form ◽  
Milling Cutter ◽  
Good Surface ◽  
2.5D Milling ◽  
Free Form Surfaces

The machining of free form surfaces is a current and important issue in die and mould industry. Beside the complex geometry, an accurate and productive machining and good surface quality are needed. The finishing milling carried out by a ball-end or toroid milling cutter defines the surface quality, which is characterized by the surface roughness and the tool path trace. The surface quality is defined by the properties of the milling cutter, the type of surface and its position, as well as the cutting parameters. This article focuses on the z-level milling of steep surfaces by 2.5D milling strategy. The importance of the different elements of the tool path is presented, the effect of cutting parameters is investigated, and a formula to predict the surface roughness is suggested.

scholarly journals Surface Roughness Models and Their Experimental Validation in Micro Milling of 6061-T6 Al Alloy by Response Surface Methodology

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Jie Yi ◽  
Li Jiao ◽  
Xibin Wang ◽  
Junfeng Xiang ◽  
Meixia Yuan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Removal Rate ◽  
Micro Milling ◽  
Al Alloy ◽  
Machined Surface ◽  
Contour Map ◽  
Good Surface ◽  
Micro Features ◽  
Good Surface Roughness

Due to the widespread use of high-accuracy miniature and micro features or components, it is required to predict the machined surface performance of the micro milling processes. In this paper, a new predictive model of the surface roughness is established by response surface method (RSM) according to the micro milling experiment of 6061-T6 aluminum alloy which is carried out based on the central composite circumscribed (CCC) design. Then the model is used to analyze the effects of parameters on the surface roughness, and it can be concluded that the surface roughness increases with the increasing of the feed rate and the decreasing of the spindle speed. At last, based on the model the contour map of the surface roughness and material removal rate is established for optimizing the process parameters to improve the cutting efficiency with good surface roughness. The prediction results from the model have good agreement with the experimental results.

Surface Roughness in High Feed Turning with Wiper Insert

2008 ◽  
Vol 375-376 ◽  
pp. 406-410 ◽  
Author(s):  
Zhan Qiang Liu ◽  
Peng Zhang ◽  
Peng Guo ◽  
Xing Ai
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Machined Surface ◽  
Good Surface ◽  
Corner Radius ◽  
Number Of Factors ◽  
Machined Surface Roughness ◽  
High Feed ◽  
Good Surface Roughness ◽  
Coated Carbide

Surface roughness in a turning operation is affected by a great number of factors. Two of the most important factors are feed rate and the size of the corner radius. Surface roughness can be roughly determined to increase with the square of the feed rate and decrease with increased size of the corner radius. However, wiper insert geometries changed this relationship with the capability to generate good surface roughness at relatively higher feeds by transferring small part of the round insert edges into the straight cutting edges of the pointed insert. The principle of how wiper inserts behave different from conventional inserts as to the effects on the surface roughness is explored in this paper. Experimental study of the surface roughness produced in the turning of hardened mild steels using coated carbide tools with both conventional and wiper inserts is conducted. The test results prove the effectiveness of the wiper inserts in providing excellent surface roughness. The results also suggest that the use of the wiper insert is an effective way that significantly increases cutting efficiency without changing the machined surface roughness in high feed turning operations.

Research and Application of Wire Cutting Mold Surface Roughness

2012 ◽  
Vol 217-219 ◽  
pp. 1577-1580
Author(s):  
Xiao Long Shen ◽  
Lai Xi Zhang ◽  
Nan Lin Yu
Keyword(s):  
Surface Roughness ◽  
Theoretical Analysis ◽  
Surface Quality ◽  
High Speed ◽  
Mold Surface ◽  
Surface Processing ◽  
Surface Machining ◽  
Good Surface ◽  
Wire Cutting ◽  
Discharge Gap

The article aimed at mold parts surface machining, has been studied high speed wire cutting technology. Explored the process evaluation factors which impact wire cutting mold based on the theoretical analysis of the wire cutting discharge gap and the surface processing finish of the mold parts. By studying the two main elements which affect the mold parts surface roughness processing, measures of improve and enhance wire cutting mold surface roughness are proposed. Only the comprehensive account of various factors can obtain mould parts processing good surface quality. The research methods and conclusion have provided reference on solving the problem of mold parts surface roughness by WEDM.

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