Research on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal Ultrasonic Vibration Assisted Milling

In order to study the influence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a significant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the influence of ultrasonic vibration on cutting force and cutting temperature decrease. There are adverse effects on surface roughness after ultrasonic vibration superposition. The influence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

The generation of Tollmien–Schlichting waves by free-stream turbulence in transonic flow

This paper studies the generation of Tollmien–Schlichting waves by free-stream turbulence in transonic flow over a half-infinite flat plate with a roughness element using an asymptotic approach. It is assumed that the Reynolds number (denoted Re) is large, and that the free-stream turbulence is uniform so it can be modelled as vorticity waves. Close to the plate, a Blasius boundary layer forms at a thickness of $$O(\mathrm{{Re}}^{-{1}/{2}})$$ O ( Re - 1 / 2 ) , and a vorticity deformation layer is also present with thickness $$O(\mathrm{{Re}}^{-{1}/{4}})$$ O ( Re - 1 / 4 ) . The report shows that there is no mechanism by which the vorticity waves can penetrate from the vorticity deformation layer into the classical boundary layer; therefore, a transitional layer is introduced between them in order to prevent a discontinuity in vorticity. The flow in the interaction region in the vicinity of the roughness element is then analysed using the triple-deck model for transonic flow. A novel asymptotic expansion is used to analyse the upper deck, which enables a viscous–inviscid interaction problem to be derived. In order to make analytical progress, the height of the roughness element is assumed to be small, and from this, we find an explicit formula for the receptivity coefficient of the Tollmien–Schlichting wave far downstream of the roughness.

Improving the Properties of Laser-Welded Al–Zn–Mg–Cu Alloy Joints by Aging and Double-Sided Ultrasonic Impact Compound Treatment

To improve the loose structure and serious porosity of (Al–Zn–Mg–Cu) 7075 aluminum alloy laser-welded joints, aging treatment, double-sided ultrasonic impact treatment (DSUIT), and a combination of aging and DSUIT (A–DSUIT) were used to treat joints. In this experiment, the mechanism of A–DSUIT on the microstructure and properties of welded joints was analyzed. The microstructure of the welded joints was observed using optical microscopy, scanning electron microscopy, and electron backscatter diffraction (EBSD). The hardness and tensile properties of the welded components under the different processes were examined via Vickers hardness test and a universal tensile testing machine. The results showed that, after the aging treatment, the dendritic structure of the welded joints transformed into an equiaxed crystal structure. Moreover, the residual tensile stress generated in the welding process was weakened, and the hardness and tensile strength were significantly improved. After DSUIT, a plastic deformation layer of a certain thickness was generated from the surface downward, and the residual compressive stress was introduced to a certain depth of the joint. However, the weld zone unaffected by DSUIT still exhibited residual tensile stress. The inner microhardness of the joint surface improved; the impact surface hardness was the largest and gradually decreased inward to the weld zone base metal hardness, with a small improvement in the tensile strength. Compared with the single treatment process, the microstructural and mechanical properties of the welded joint after A–DSUIT were comprehensively improved. The microhardness and tensile strength of the welded joint reached 200 HV and 615 MPa, respectively, for an increase of 45.8% and 61.8%, respectively. Observation of the fractures of the tensile specimens under the different treatment processes showed that the fractures before the aging treatment were mainly ductile fractures while those after were mainly brittle fractures. After DSUIT of the welded joints, a clear and dense plastic deformation layer was observed in the fracture of the tensile specimens and effectively improved the tensile properties of the welded joints. Under the EBSD characterization, the larger the residual compressive stress near the ultrasonic impact surface, the smaller the grain diameter and misorientation angle, and the lower the texture strength. Finally, after A–DSUIT, the hardness and tensile properties improved the most.

Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Effect of milling on the microstructure and mechanical property of austenite stainless steel

A milling induced deformation layer of Z3CN20.09M, 304L and 316L austenite stainless steel (SS) was investigated by electron backscatter diffraction (EBSD), transmission electron microscopy (TEM) and a nanoindenter. The results indicated that the deformation layer was formed with a depth of about 200 μm, including a nanocrystalline layer within the range of 3 μm at the subsurface and followed by a large amount of persistent slip bands (PSBs). The significant plastic deformation was observed on the cross section of deformation layer with a range of about 80 μm for Z3CN20.09M and 304L SS, while being only about 30 μm for 316L SS. The highest residual stress tested on the milled surface reached about 1000 MPa, which can be attributed to the fact that a deformed martensite phase was formed at the surface during the milling operation. The nanohardness increased by 20-60 % on the cross section of the deformation layer as compared to the matrix.

Influence of Surface Ultrasonic Rolling on Microstructure and Corrosion Property of T4003 Ferritic Stainless Steel Welded Joint

In this paper, the effect of surface ultrasonic rolling treatment (SURT) on surface properties of T4003 cold metal transfer (CMT) welded joints was studied. Surface topography and microstructure changes of the welded joint surface before and after SURT were observed by optical microscope and scanning electron microscope. The hardness and residual stress distribution of welded joint were measured by a microhardness tester and X-ray diffractometer. The change of corrosion resistance of welded joints was studied by electrochemical polarization curve measurement. The results show that surface roughness (Ra) of the weld zone, heat affect zone (HAZ), and base metal after SURT was reduced to 0.320 μm, 0.156 μm, and 0.227 μm, respectively, and surface morphology became smooth. The plastic deformation layer and working hardening layer were formed at the welded joint. The degree of plastic deformation of the weld zone was more serious than that in the base metal, and grains in weld zone was obviously refined. The thickness of plastic deformation layer was about 100 μm. The surface hardness in the weld zone was highest, which is about 420 HV. The refinement of grains and the increase of surface hardness can improve the fatigue life of welded joint. After SURT, the residual stress in the welded joint changes from residual tensile stress to residual compressive stress, which can also improve fatigue life of the welded joint. Surface corrosion resistance of welded joints after SURT was improved due to smooth surface and the formation of fine grains layer.

Experimental Investigation on the Wear and Damage Characteristics of Machined Wheel/Rail Materials under Dry Rolling-Sliding Condition

To guarantee the smooth operation of trains, rail grinding and wheel turning are necessary practices to remove surface defects. Surface integrity of machined wheel/rail materials is significant to affect their tribological performance. In this paper, firstly, the wheel specimens were turned by a CNC lathe and the rail specimens were ground by a cylindrical grinding machine with various machining parameters. Then, the wear and damage behavior of the machined wheel/rail discs was systematically investigated via a twin-disc wear testing apparatus under dry rolling-sliding condition. The experimental results show that the surface hardness of rail discs after machining is slightly higher than that of wheel discs, while the surface roughness and plastic deformation layer of wheel discs are much larger than those of rail discs. The surface hardness increase degree of rail discs and their thickness of plastic deformation layer are greater than those of wheel discs after the rolling-sliding test. The wear loss of wheel discs is much larger than that of rail discs. Surface roughness, hardness and plastic deformation layer of wheel/rail discs after machining exert a comprehensive effect on the wear behavior, and friction pair with appropriate original surface hardness and roughness generates the smallest amount of wear loss.

Residual Stress and Microstructure Characterization of 34CrMo4 Steel Modified by Shot Peening

34CrMo4 steel is widely used for drill stem in oil exploration, because of its excellent properties, such as favorable hardenability, shock absorption, less tendency of temper brittleness, and eminent wear resistance. In this study, the main works are residual stress test and microstructure characterization of 34CrMo4 steel upon various shot peening treatments. The residual stress distribution with effect depth was studied upon the shot peening. Face-to-face paste sample preparation method is required for continuous observation for microstructure evolution of shot-peened specimen from the treat surface to matrix. Grain refinement, lath structure, and precipitates are clearly observed in the gradient deformation layer.

Influence of Contact Stress on Surface Microstructure and Wear Property of D2/U71Mn Wheel-Rail Material

To investigate the relationship between surface microstructure and wear mechanism in D2/U71Mn wheel-rail material under different contact stress conditions, rolling wear tests using a GPM-40 wear machine to simulate the wheel-rail operation was performed. After wear tests, an optical microscope (OM), scanning electron microscope (SEM) and micro-hardness testers were used to characterize the microstructure and fatigue wear cracks. The results show that the thickness of the plastic deformation layer and surface hardness is increased with the increase of contact stress. Under high contact stress condition (1200 MPa), the severe plastic deformation layer led to the formation of fatigue wear of wheel-rail samples. Under a contact stress of 700 MPa, the wear mechanism of samples is adhesive wear and wear rate is low. With the increase of contact stress, the fatigue cracks are gradually severe. Under a contact stress of 1200 MPa, the wear mechanism of samples becomes fatigue wear and the fatigue wear cracks cause the increase of wear rate. The fatigue wear can accelerate the wear failure of wheel-rail samples. The fatigue wear cracks of wheel samples are severer than that of rail samples due to both the rate of plastic strain and the content of proeutectoid ferrite.