Turning Test and Simulation of Difficult to Cut Materials 300M in Aviation

2014 ◽  
Vol 800-801 ◽  
pp. 208-213
Author(s):  
Hui Ping Zhang ◽  
Yi Nan Lai ◽  
Chong Xun Wang ◽  
Xu Du
Keyword(s):  
Cutting Temperature ◽  
High Strength ◽  
Least Square Method ◽  
Least Square ◽  
Machining Accuracy ◽  
Linear Regression Models ◽  
Element Analysis ◽  
Cutting Velocity ◽  
Structural Parts ◽  
Materials Used

Turning process properties of difficult-to-cut materials used in aeronautics are often associated with the machining accuracy and surface quality of aerospace structural parts. This study presents the influence of cutting velocity, feed rate and back cutting depth on cutting force and cutting temperature during dry turning of ultra-high strength 300M steel, where the linear regression models of cutting forces and cutting temperature are constructed by using least square method, and the regression coefficients of these models are verified by significance tests. Meanwhile, the temperature distribution and chip in turning machining are also achieved by finite element analysis.

Experimental Study on Coupling Characteristics of Cutting Heat and Cutting Vibration Under Different Tool Wear States

2021 ◽  
Author(s):  
Songyuan Li ◽  
Shuncai Li ◽  
Yuting Hu ◽  
Eugene Popov
Keyword(s):  
Regression Model ◽  
Temperature Rise ◽  
Mechanical Vibration ◽  
Cutting Temperature ◽  
Least Square Method ◽  
Cutting Parameters ◽  
Least Square ◽  
Cutting Heat ◽  
Cutting Vibration ◽  
Coupling Characteristics

Abstract The thermo-mechanical-vibration coupling characteristics of turning system has always been an important research topic in the field of machining, and the material, states and performance of cutting tools will directly affect this coupling characteristics. In this paper, a synchronous testing system for cutting temperature and cutting vibration is built to collect the cutting temperature and cutting vibration near the tip of three worn tools D1 (new blade), D2 (moderately worn blade) and D3 (severely worn blade). Based on the test data and the grey correlation theory, the coupling characteristics of cutting temperature rise and cutting vibration of tools in different wear states are analyzed. Based on the experimental data and least square method, (1) the regression model of cutting temperature rise about cutting vibration and cutting parameters (2) the regression model of cutting vibration about cutting temperature rise and cutting parameters have been established respectively. The undetermined parameters and correlation coefficients are obtained by MATLAB software programming. The research show that the coupling of cutting heat and cutting vibration of tools D1 and D2 is one-way coupling, that is, cutting vibration significantly affects cutting heat, but cutting heat has little effect on cutting vibration, while the coupling of cutting heat and cutting vibration of tool D3 is a bidirectional coupling.

A Study of Cutting Temperatures in Turning Carbon-Fiber-Reinforced-Plastic (CRFP) Composites with Nose Radius Tools

2015 ◽  
Vol 649 ◽  
pp. 38-45 ◽  
Author(s):  
Chung Shin Chang
Keyword(s):  
Carbon Fiber ◽  
Cutting Temperature ◽  
High Strength ◽  
Heat Transfer Analysis ◽  
Fiber Reinforced ◽  
Nose Radius ◽  
Element Analysis ◽  
Reinforced Plastics ◽  
Inverse Heat Transfer ◽  
Carbon Fiber Reinforced

Nine kinds of chamfered main cutting edge nose radius tools were used in turning of high-strength carbon-fiber-reinforced-plastics (CFRP) materials to study the cutting temperature of tip's surface. A new cutting temperature model using the variations of shear and friction plane areas occurring in tool nose situations are presented in this paper. The frictional forces and heat generated in the cutting process are calculated by using the measured cutting forces and the theoretical cutting analysis. The heat partition factor between the tip and chip is solved by using the inverse heat transfer analysis, which utilizes temperature on the K type carbide tip’s surface measured by infrared as the input. The tip’s carbide surface temperature is determined by finite element analysis (FEA) and compared with temperatures obtained from experimental measurements. Good agreement demonstrates the proposed model.

Milling Force Modeling and Experimental Research of 300M Ultra High Strength Steel

2014 ◽  
Vol 800-801 ◽  
pp. 53-60 ◽  
Author(s):  
Hui Ping Zhang ◽  
Chong Xun Wang ◽  
Yi Nan Lai ◽  
Wen Juan Zheng
Keyword(s):  
High Strength Steel ◽  
Orthogonal Experiment ◽  
Multiple Linear Regression Model ◽  
High Strength ◽  
Least Square Method ◽  
Cutting Parameters ◽  
Least Square ◽  
Depth Of Cut ◽  
Milling Force ◽  
Ultra High Strength Steel

300M ultra high strength steel, a new type of steel with broad prospects for development, has good mechanical properties, and is widely used for manufacture of aircraft landing gear. In order to reveal influence law of cutting parameters on milling force of 300M ultra high strength steel, the influence law of feed rate, milling width, and depth of cut and spindle speed on milling force is firstly studied through the single factor experiments in this paper. Secondly, the influence level of experimental factors is compared by orthogonal experiment. Finally, combined with orthogonal test data and the least square method, the multiple linear regression model of milling force in 300M ultra high strength steel milling is built. The accuracy of the model has been verified well by experimental verification, which has the guiding significance to reveal the milling mechanism and actual production.

scholarly journals Optimization Design of an Axial Split-Phase Bearingless Flywheel Machine with Magnetic Sleeve and Pole-Shoe Tooth by RSM and DE Algorithm

Energies ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1256 ◽  
Author(s):  
Zhiying Zhu ◽  
Jin Zhu ◽  
Hailang Zhu ◽  
Xi Zhu ◽  
Yajie Yu
Keyword(s):  
Response Surface ◽  
Optimization Design ◽  
Least Square Method ◽  
Basic Structure ◽  
Optimization Method ◽  
Tooth Profile ◽  
Least Square ◽  
Initial Structure ◽  
Element Analysis ◽  
De Algorithm

In order to improve the suspension and torque performance of a bearingless flywheel machine, a new type of axial split-phase bearingless flywheel machine with a magnetic sleeve and pole-shoe tooth is analyzed and optimized as described in this paper. Based on the basic structure and working characteristics of the machine, the response surface methodology (RSM) and differential evolution (DE) algorithm are adopted to further optimize the parameters of the stator teeth of the machine to improve the radial space utilization and motor output performance. Firstly, the Box–Behnken design (BBD) and finite element analysis (FEA) are combined to select the representative optimization parameter combinations to establish the sample data space, and the response surface models of machine torque and suspension force are established using the least square method. Besides this, the DE algorithm is employed to obtain the optimal tooth profile parameter configuration for the multi-objective optimization of machine performance. Finally, the output performances of the machine before and after optimization are compared under initial and optimized winding turns. The results show that, compared with the initial structure, the average torque and suspension force of the optimized machine increase by 36.46 % and 108.22% respectively, which demonstrates the effectiveness of the tooth profile optimization method. At the same time, an experimental prototype is also produced, laying the experimental foundation for further practical exploration.

A Practical Algorithm for Compensating the Whole-Error of On-Machine Measurement

2010 ◽  
Vol 431-432 ◽  
pp. 462-465
Author(s):  
Sheng Bao ◽  
Ping Fa Feng
Keyword(s):  
Reference Frame ◽  
Machine Tools ◽  
Least Square Method ◽  
Least Square ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Valid Data ◽  
Practical Algorithm ◽  
Normal Vectors ◽  
Structural Parts

The On-machine measurement is usually based on the data of points. When data come from the CNC machine tools, the information they carry may be invalid. Therefore, it is unsuitable to compensate the errors by rotating and translating all data. In this paper, a practical algorithm is proposed to compensate the errors. Firstly, the valid data are picked out and sorted according to their normal vectors. By using the least square method, an error reference frame is constructed. Then the relation between the compensation values and coordinates of the theoretical points is derived. Finally, an example of aircraft structural parts is presented to validate the design.

A Method for Enhancing the Accuracy of On-Machine Inspection for Five-Axis CNC Machines

2012 ◽  
Vol 426 ◽  
pp. 351-354
Author(s):  
Sheng Bao ◽  
Xi Zhang ◽  
Ping Fa Feng
Keyword(s):  
Coordinate System ◽  
Reference Frame ◽  
Least Square Method ◽  
Practical Method ◽  
Least Square ◽  
Inspection System ◽  
Cnc Machines ◽  
Structural Parts ◽  
Five Axis ◽  
Valid Information

The efficiency of manufacturing structural parts can be improved by using on-machine inspection system. It is difficult to separate the valid information from hundreds of points and correct the errors by rotating and translating the workpiece coordinate system directly, especially for five-axis CNC machines. In this paper, a practical method is designed to correct errors easily. By using the least square method, an error reference frame is constructed, and the relation between the compensation values and coordinates of the theoretical points is derived. An example of aircraft structural parts is presented to validate the design.

Study on Machinability of 35CrMnSiA Steel in Hard Turning Process

2006 ◽  
Vol 532-533 ◽  
pp. 349-352
Author(s):  
Wen Xiang Zhao ◽  
Si Qin Pang ◽  
Zhen Hai Long ◽  
Xi Bin Wang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
High Strength ◽  
Depth Of Cut ◽  
Turning Process ◽  
High Speed Turning ◽  
Cutting Velocity ◽  
Strength Alloy

35CrMnSiA, is a kind of important engineering materials that used widely in modern manufacturing fields. The machinability of 35CrMnSiA Steel with hardness of HRc40±2 in high speed turning process was studied in this paper. It is concluded that, when high speed turning of this ultra-high strength alloy steel, the chief wear mode of ceramics is the crater on rake faces; the interaction of depth of cut and feed rate is one of statistic significant effects on cutting force; the interaction of cutting velocity of cut and feed rate is one of statistic significant effects on surface roughness Ra; besides, the empirical formula of average cutting temperature, cutting forces, surface roughness Ra, was established.

A Study of Cutting Temperatures in Turning Carbon-Fiber-Reinforced-Plastic (CRFP) Composites with Nose Radius Worn Tools

2018 ◽  
Vol 26 (1) ◽  
pp. 19-26 ◽  
Author(s):  
Chung-Shin Chang
Keyword(s):  
Carbon Fiber ◽  
Cutting Temperature ◽  
High Strength ◽  
Heat Transfer Analysis ◽  
Fiber Reinforced ◽  
Nose Radius ◽  
Element Analysis ◽  
Reinforced Plastics ◽  
Inverse Heat Transfer ◽  
Carbon Fiber Reinforced

Nine kinds of carbide nose radius worn tools were used in turning of high-strength carbon-fiber-reinforced-plastics (CFRP) materials to study the cutting temperature of tip's surface. A new cutting temperature model using the variations of shear and friction plane areas occurring in tool nose wear situations are presented in this paper. The frictional forces and heat generated in the cutting process are calculated by using the measured cutting forces and the theoretical cutting analysis. The heat partition factor between the tip and chip is solved by using the inverse heat transfer analysis, which utilizes temperature on the K type carbide tip's surface measured by infrared as the input. The tip's surface temperature is determined by finite element analysis (FEA) and compared with temperatures obtained from experimental measurements. Good agreement demonstrates the proposed model.

scholarly journals The application of Chaboche model in uniaxial ratcheting simulations

2020 ◽  
Vol 44 (2) ◽  
pp. 57-61
Author(s):  
Marta Wójcik ◽  
Andrzej Skrzat
Keyword(s):  
Kinematic Hardening ◽  
Strain Curve ◽  
Optimization Procedure ◽  
Least Square Method ◽  
Least Square ◽  
Compression Tests ◽  
Loading Test ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Chaboche Model

AbstractThis article presents the application of Chaboche nonlinear kinematic hardening model in simulations of uniaxial ratcheting. First, the symmetrical strain-controlled cyclic tension/compression tests for PA6 aluminum samples were done. Using the experimental stress–strain curve, initial material hardening parameters were determined by the ABAQUS software. The experimental curve was compared with the numerical one. For better fitting of both curves, the optimization procedure based on the least-square method was applied. Using the determined hardening parameters, numerical simulations of the ratcheting were done by the finite element analysis software. Numerical results were then compared with the experimental data obtained in the stress-controlled cyclic loading test.

The Study on Rubber’s Constitutive Model about Parameters Identification and the Effect of Fitting Error

2012 ◽  
Vol 503-504 ◽  
pp. 1094-1099
Author(s):  
Wen Tao Wang ◽  
Wen Bin Shang Guan
Keyword(s):  
Biaxial Tension ◽  
Constitutive Models ◽  
Least Square Method ◽  
Least Square ◽  
Test Material ◽  
Model Parameters ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Hyper Elastic ◽  
Fitting Accuracy

Fitting accuracy of hyper-elastic constitutive models of rubber and parameter identification of the models play important roles in the finite element analysis of rubber components. In this paper, to obtain stress-strain characteristics, uniaxial and planar as well as biaxial tension of a standard rubber sample are measured. Model parameters of three kinds of classic constitutive models are identified using least square method. Then, the fitting accuracy among different models is compared. The comparison shows that the fitting accuracy is getting higher when the test material strain is increased. Also, it can be concluded that Mooney-Rivlin model and Van der Waals model as well as third-order Ogden model have relatively stable fitting accuracy.

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