Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q2: β∈[0°, 90°]) or lower left (Q3: β∈[90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q1: β∈(−90°, 0°]) or upper left (Q2: β∈[0°, 90°)).

Micro Electrical Discharge Machining Thermal Effect on Micro-Cracks Generation on Silicon Material

Various novel 3D micro machining technologies were researched and developed for silicon micro mechanical system fabrication. Micro EDM is one of them. The material removal mechanism is thermal sparking erosion and is completely independent with regards to the crystalline orientation of silicon, therefore there is no orientation constraint in processing the complex 3D geometry of silicon wafers. As thermal sparking implied, the process features local area high temperature melting and evaporating, and this characteristic has an adverse side-effect on the sparked surface integrity. One important concern is the generation of micro cracks, which would provide an adverse effect on the fatigue life of the micro feature element made of silicon. For this consideration, in this paper, with the experiment and SEM picture analysis approach, the author explored the micro crack generation characteristics on mono crystalline silicon wafers under micro EDM with available sparking energies and on the different crystal orientation surface machining. The generation of micro cracking is not only related with the sparking energy but also related with the crystalline orientation. The {100} orientation is the strongest surface to resist crack generation. For a strong-doped P type silicon wafer, there exists a maximum crack energy threshold. If single sparking energy is over this threshold, micro cracks unavoidably would be generated on any orientation surface. Two types of chemical etching post processes that can remove cracks on sparked surfaces are also tested and discussed.

Characteristics of the Polishing Effects for the Stainless Tubes in Magnetic Finishing with Gel Abrasive

Magnetic abrasive finishing (MAF) is a fast, high efficiency and high-precision polishing method on the surface machining of the metals. Furthermore, MAF also can be utilized to polish the stainless tubes in industrial applications; however, stainless tubes are often a non-magnetic material that makes it difficult for the magnetic field line to penetrate into the stainless tubes, thus reducing the magnetic forces in the inner tubes polishing. That is why stainless tubes are not easy to finish using traditional MAF. Therefore, magnetic finishing with gel abrasive (MFGA) applies gels mixed with steel grit and abrasives that were developed to improve the polishing efficiency and surface uniformity of the steel elements. In this study, a guar gum or silicone gel mixed with steel grit and silicon carbides are used as the magnetic abrasive gel to polish the stainless inner tubes. A DC motor was used to control the rotation speed of the chuck and an AC induction motor connected with an eccentric cam to produce the reciprocating motion of the workpiece were utilized to finish the inner surface of stainless tubes in the polishing process. The parameters of abrasive concentration, abrasive particle sizes, rotation speeds of motor and electric currents were used to investigate the surface roughness and the removal of materials from the stainless tubes. The experimental results showed that since guar gum had better fluidity than the silicone gel did, guar gum created excellent polishing efficiency in MFGA. Furthermore, the surface roughness of the stainless tube decreased from 0.646 μm Ra to below 0.056 μm Ra after processing for 30 min with the parameters of current 3A, gel abrasive with guar gum, rotational speed 1300 rpm and vibration frequency 4 Hz.

Diamond tool wear monitoring by sensory analysis in milling of absolute black granite

Diamond tools suitable for machining operations of natural stones can be divided into two groups: cutting tools, including blades, the circular blades and the wires, and the surface machining ones, involving mills and grinders, that can be of different shapes. For the stone sawing process, the most adopted tool type is the diamond mill, whose duration and performance are influenced by various elements such as: the mineralogical characteristics of the material to be machined; the working conditions such as the depth of cut, the feed rate and the spindle speed; the production process of the diamond segment and the characteristics of both the matrix and the diamond, such as the size, the type and the concentration of the diamonds and the metal bond formulation hardness. This work allows to indirectly assess the wear of sintered diamond tools by signal analysis (in time and frequency domain) of the cutting force components acquired in the process. The results obtained represent a fundamental step for the development of a sensory supervision system capable of assessing the tool wear and hence to modify the process parameters in process, in order to optimize cutting performance and tool life.

Effect of the chassis parts surface condition from high-strength titanium alloy VT-22 in the process of fatigue tests

The research focuses on the influence of the surface condition on the resource of high-strength titanium alloy VT-22 landing gear details during fatigue tests. The tests were performed on special facilities that simulate the workload on a rod detail at the stage of extending and retraction of the landing gear. Fatigue tests were performed on four rods. Rods № 1-3 were destroyed at the lugs level, rod №4 withstood the entire cycle of loads, and was examined in an undamaged state. It was found that the cause of the failure of the rod №1 was axial play formation as a result of bracket lug deformation, which led to shock loads on the lug of the rod №1 during the tests. The destruction of the rod №2 could be caused by the shock axial loads due to changes in the characteristics and load values of the facility on the rod №2. The priority factor influencing the premature failure of the rod №3 was the high risks from surface machining in the most loaded part of the rod №3, namely at the R-junction of the cylindrical part to the lug. The presence of surface defects formed during the manufacturing stage, as well as the presence of deep scratches in the area with high load reduce the life of rod № 3 fivefold compared to the undamaged rod № 4, which had no visible surface defects. Surface damage detected in the non-chromized area of the rods can be eliminated by blasting with subsequent surface polishing, which will provide the required resource of the detail (rod № 4). Keywords: high-strength titanium alloy VT-22, rod, fatigue tests, surface defects, structure of the surface layer.

Examination of wood adhesive bonds via MicroCT: The influence of pre-gluing surface machining treatments for southern pine, spotted gum, and Darwin stringybark timbers

The successful manufacturing of glulam from several important Australian commercial timbers is quite challenging due to difficulties in gluing. Improvements in adhesive bond performance of spotted gum, Darwin stringybark, and southern pine timber have been achieved using alternative pre-gluing surface machining methods, e.g., face milling and sanding-post planing, when compared to conventional planing methods. In order to improve the understanding of the effects that different surface machining methods have on adhesive bond performance, this study used micro X-ray computed tomography and microscopy to assess key adhesive bond criteria. There was a considerable loss in the amount of adhesive after the wet and dry test cycles for all species. There was also an extremely high frequency of voids in the glue lines for all species, which would negatively impact bond strength and durability. Face mill prepared timber boards resulted in thicker glue lines and greater resistance to adhesion loss, compared to boards prepared via planing. For the two hardwood species, face milling also resulted in greater adhesive penetration; however, for southern pine, there were no significant differences in adhesive penetration between the three surface machining treatments. Adhesive penetration was much deeper in southern pine compared to spotted gum and Darwin stringybark.