Modeling of formation regularities of conical surfaces

The scheme of processing conical surfaces by grinding them to a flat tool is considered and a technical solution for the implementation of such processing is proposed. Using the created device allows implementing the group method of forming conical parts with a deviation of the generatrix of the cone from straightness of not more than ± 0.00012 mm. A mathematical model of the patterns of removal of stock from a conical part with a flat tool is developed. A formula is obtained for calculating the modulus of the sliding velocity at any point on the processed conical surface, which implements engineering methods for controlling the shaping of conical parts without conducting preliminary labor-intensive experimental studies. An optimization technique for the adjustment parameters of technological equipment was proposed. The most effective axicon processing modes were revealed at the stages of preliminary, medium and fine grinding, as well as at the polishing stage, depending on the technological heredity of the workpiece from the point of view of distribution of the stock to be removed over its surface. It has been established that changes in the eccentricity between the axes of rotation of the tool and the faceplate as well as the amplitudes of the reciprocating rotational movements of the latter practically do not affect both accuracy and processing productivity, therefore, in practice, these parameters can not be optimized, but their average values can be assigned. The operating modes of the basic lever grinding and polishing machine are established, at which the required accuracy of the working surface of the tool is provided, which directly affects the straightness of the generatrix of the cone. Studies of the regularities of the shaping of the side surface of a conical lens in the conditions of free grinding are carried out and the adjustment parameters of technological equipment that affect the quality and productivity of the processing process are determined.

Deformation due to sliding of single and woven carbon tows in dry and epoxy-lubricated conditions

This experimental work focuses on the evaluation of deformation mechanisms due to sliding between carbon fiber tows with a flat tool in dry and lubricated with liquid resin conditions. The experiments were carried out on manually woven and single tows. The effect of angle between tow axes and sliding direction was also studied. The topography of the tows in contact with a sliding transparent glass plate was measured with a 3D optical microscope before and after sliding. These measurements revealed a decrease of roughness with sliding in all tested conditions, a contraction of lubricated single tows in perpendicular to sliding orientation, and high residual displacements in lubricated woven tows in 0°/90° orientation and dry single tows in perpendicular to sliding orientation.

Effects of Shoulder Geometry on Microstructures and Mechanical Properties of Probeless Friction Stir Spot Welded Aluminum 7075-T651 Sheets

In this work, three types of probeless tools (archimedes, involute, and concave tools) were designed. A 7075-T651 sheet of 1.0 mm thickness was welded using the designed probeless tools. It was found that the stir zone and hook defect varied a lot for different joints. Plunge depth was the dominant process parameter for joint property. The joint’s maximum failure load (5.73 kN) was obtained with the concave tool when the target plunge depth was 0.55 mm. Two typical joint fracture modes (shear fracture and plug fracture) were found using three designed tools with different plunge depths, rotation speeds, and dwell times. Shoulder geometry presented little influence on heat generation. Compared with involute grooves, archimedes grooves showed to be more effective on the material flow. The properties of the joints with the archimedes tool were more sensitive to welding parameters. Compared with the flat tool, the concave tool decreased the escape of plasticized material, improved the forge force, and optimized the metallurgical bond at the interface.

Simulation of axicon processing area on technological equipment

Annotation. An analytical expression is obtained for engineering calculation of the regularities of removing the allowance from the flat surface of the part (a rectangle in the form of a flat glass plate of considerable thickness with holes for axicon blanks), which participates in relative and portable movement on the surface of a rotating tool (faceplate) and is in a power circuit with it, which provides automatic self-installation of lapping surfaces. A scheme is proposed for dividing the lapping surfaces of a flat tool and part into ring zones and sectors, resulting in the formation of elementary platforms with reference (calculated) points in their center. Analytical expressions are obtained for calculating the coordinates of these points. The kinematics of the relative movement of the tool and the straightener without oscillation of the upper link is considered, while the sliding of the conjugate surfaces takes place due to rotation of the tool and the straightener installed with a certain eccentricity. An expression is obtained for determining the sliding speed at any point of contact of the conjugate surfaces. Modeling when dealing with relative and portable movement of the upper unit, which allowed obtaining a formula for the slip velocity of the straightener relative to the tool that allows calculation the path of friction in a particular zone in different modes of operation of technological equipment. Modeling can be used as the basis for creating a method for controlling the process of forming conical optical parts (axicons) on serial lever grinding and polishing machines with a flat tool under free lapping conditions, which provide the possibility of obtaining axicons with a deviation of the forming cone from the straightness of no more than ±0.00012 mm.

Study on Adhesion With Stress and Temperature in Drilling of Aluminum Alloy

Aluminum alloys have been widely used for automobile and aircraft parts. In cutting of aluminum alloy, adhesion sometimes occurs to deteriorate surface finish. The study discusses the adhesion characteristics in drilling of aluminum alloy (A7075) with a flat tool at a point angle of 180 degrees. The adhesion volumes on the rake face of the tool were measured in drillings of blind holes for the cutting speeds and the feed rates. Then, the stress and the temperature distributions were estimated in the cutting simulation. In the simulation, the cutting force is predicted in the chip flow model based on the minimum cutting energy. The cutting temperature is analyzed in Finite volume method using the result in the cutting force prediction. The adhesion volumes are associated with the stress and temperature on the rake face. The adhesion volume becomes large in the temperature ranged from 400 to 500 K. The adhesion volume increases with the stress up to 500 MPa.

Effect of Rotational Speed and Flat Tool Diameter on the Zn Distribution of the Dissimilar Metals Friction Stir Spot Welded between Aluminum Alloy 5083 H321 and Galvanized Steel

Friction stir spot welding (FSSW) was developed to join the dissimilar materials as an alternative for replacing the resistance spot welding (RSW). In the case of dissimilar metals welded between aluminum and galvanized steel, Zn can decompose and diffuse in both steel and aluminum so it can increase the joint strength. Due to this reason, it is important to explore the Zn distribution based on the parameter of the friction stir spot welding. The lap joint configuration was used in this work where aluminum plate was placed on the top of steel. Aluminum thickness was 3 mm, while steel thickness was 1 mm. The constant depth of plunge, dwell time, and penetration rate were 2.7 mm, 3 seconds, and 0.9 mm/sec respectively. Flat tool with diameters of 10 mm, 12 mm and 14 mm were used for FSSW processes and for each flat tool diameter, four levels of the rotational speed of 1000 rpm, 1200 rpm, 1600 rpm and 2000 rpm were performed. The Zn distribution was evaluated using the SEM and EDS analysis. Due to the heat generation during FSSW process, materials around the tools will soften and then flow to follow the centrifugal force. The rotational speed and the flat tool diameter affected the distance and the shape of Zn diffusion flow. The distance of Zn diffusion both horizontal and vertical direction increased as increasing the rotational speed and the flat tool diameter.

Benchmarking of Direct and Indirect Friction Tests in Micro Forming

In this study the application of a simulative sliding friction test at micro scale is suggested. Two work piece specimens are upset against opposing sides of a flat tool element. The tool element is then pulled out while the resulting friction force F is measured. The test principle offers several advantages when compared against the DEC-test, including easy visual inspection of tool and work piece surfaces, continuous measurement of friction coefficient over the complete sliding length and less sensitivity to mechanical tolerance deviations of work piece and tool elements.