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Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting

Frontiers of Mechanical Engineering 2021年第2期16卷 285-297页

作者： Yidan WANG Renke KANG Yan QIN Qian MENG Zhigang DONG Key Laboratory for Precision and Non-traditional machining Technology of Ministry of Education Dalian University of TechnologyDalian 116024China

Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb *** machining quality is influenced by ultrasonic cutting parameters,as well as tool orientations,which are determined by the multi-axis machining requirements and the angle control of the cutting ***,in existing research,the effect of the disc cutter orientation on the machining quality has not been studied in depth,and practical guidance for the use of disc cutters is *** this work,the inclined ultrasonic cutting process with a disc cutter was analyzed,and cutting experiments with different inclination angles were *** theoretical residual height models of the honeycomb core,as a result of the lead and tilt angles,were established and verified with the results obtained by a linear laser displacement *** shows that the residual height of the honeycomb core,as a result of the tilt angle,is much larger than that as a result of the lead ***,the tearing of the cell wall on the machined surface was observed,and the effects of the ultrasonic vibration,lead angle,and tilt angle on the tear rate and tear length of the cell wall were *** results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining *** in the tilt angle have less effect than changes in the lead angle on the tearing of the cell *** determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell *** study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

关键词： Nomex honeycomb core disc cutter inclined ultrasonic cutting machining quality

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Improving profile accuracy and surface quality of blisk by electrochemical machining with a micro inter-electrode gap

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Chinese Journal of Aeronautics 2023年第4期36卷 523-537页

作者： Jingtao WANG Zhengyang XU Di ZHU College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

Electrochemical machining(ECM)has emerged as an important option for manufacturing the *** inter-electrode gap(IEG)distribution is an essential parameter for the blisk precise shap-ing process in ECM,as it affects the process stability,profile accuracy and surface *** IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of *** achieve micro-IEG(machining,this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse *** modelling and simulation of the blisk micro-IEG machining have been carried *** experiments of variable-parameters blisk ECM were car-ried *** results illustrated that the IEG width reduced with the progress of variable parameter *** IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 lm and 21 lm,*** profile deviation for the blade’s concave surface and convex surface are 49 lm and 35 lm,while the surface roughness reaches R_(a)=0.149 lm and R_(a)=0.196 lm,*** profile accuracy of the blisk leading/trailing edges was limited to within 91 ***-pared with the currently-established process,the profile accuracy of the blade’s concave and convex profiles was improved by 50.5%and 53.3%,*** surface quality was improved by 53.2%and 50.9%,***,the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective *** electrolytic products were dispersed on the machined surface,and their components were mainly composed of the carbide and oxide products of Ti and Nb *** results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM,which can be used in engineering practice.

关键词： Electrochemical machining Blisk IEG machining quality Surface quality

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Dependency of the pulsed electrochemical machining characteristics of Inconel 718 in NaNO_(3)solution on the pulse current

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Science China(Technological Sciences) 2022年第10期65卷 2485-2502页

作者： WANG JingTao XU ZhengYang GENG TianYu ZHU Di College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

Pulsed electrochemical machining(PECM)has attracted increasing interest as a technique to improve material dissolution localization and surface *** work systematically investigates the effects of pulse current on the surface morphology,profile accuracy,and corrosion behavior of Inconel 718(IN718)in NaNO_(3)*** behavior reveals that IN718 in NaNO_(3)solution during pulse current machining exhibited significant passive,transpassive,and re-passive *** passive film generated at the re-passive state contained some oxides and had a loose porous *** critical value for the quantity of electric charge to rupture the passive film was determined to be 26.88℃cm^(−2).The current efficiency indicates that the material removal rate of IN718 in NaNO_(3)solution during pulse current machining was *** PECM experiments indicate that the loading process of the electrical double layer was prolonged with an increased workpiece scale,i.e.,the loading process of the electrical double layer lasted for the entire pulse-on time when the workpiece scale was 100 mm^(2)at a frequency of more than 10 kHz regardless of the duty cycle.A pulse current with a short pulse length and short pulse period improved the profile accuracy,as did the low applied voltage and small workpiece *** dissolution mechanism of IN718 in NaNO_(3)solution was also investigated based on the effective pulse current ***,the leading-edge structure of a ruled blade with good dimensional accuracy and surface quality was successfully *** maximum deviations of the machined profile were effectively restricted within 0.057 mm,and the surface roughness was Ra=0.358μm.

关键词： pulsed electrochemical machining corrosion behavior current efficiency blade leading edge machining quality

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Experimental Study on Titanium Alloy Cutting Property and Wear Mechanism with Circular-arc Milling Cutters

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Chinese Journal of Mechanical Engineering 2023年第3期36卷 219-229页

作者： Tao Chen Jiaqiang Liu Gang Liu Hui Xiao Chunhui Li Xianli Liu School of Mechanical and Power Engineering Harbin University of Science and TechnologyHarbin 150080China

Titanium alloy has been applied in the field of aerospace manufacturing for its high specific strength and ***,these properties also cause general problems in the machining,such as processing inefficiency,serious wear,poor workpiece face quality,*** at the above problems,this paper carried out a comparative experimental study on titanium alloy milling based on the CAMCand *** variation law of cutting force and wear morphology of the two tools were obtained,and the wear mechanism and the effect of wear on machining quality were *** conclusion is that in contrast with BEMC,under the action of cutting thickness thinning mechanism,the force of CAMC was less,and its fluctuation was more *** flank wear was uniform and near the cutting edge,and the wear rate was *** the early period,the wear mechanism of CAMC was mainly ***,oxidative wear also occurred with ***,the surface residual height of CAMC was *** is no obvious peak and trough accompanied by fewer surface defects.

关键词： Circular-arc milling cutter Titanium alloy Ball-end milling cutter Surface quality Milling force Tool wear machining quality

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Approach for Polishing Diamond Coated Complicated Cutting Tool: Abrasive Flow machining(AFM)

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Chinese Journal of Mechanical Engineering 2018年第6期31卷 154-168页

作者： Xin-Chang Wang Cheng-Chuan Wang Chang-Ying Wang Fang-Hong Sun School of Mechanical Engineering Shanghai Jiao Tong University

Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance

关键词： Abrasive flow machining Diamond coated complicated cutting tool Surface roughness Radius of the cutting edge machining quality Tool lifetime

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Research on ultrasonic-assisted drilling in micro-hole machining of the DD6 superalloy

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Advances in Manufacturing 2020年第3期8卷 405-417页

作者： Xiao-Xiang Zhu Wen-Hu Wang Rui-Song Jiang Zhan-Fei Zhang Bo Huang Xiu-Wei Ma School of Mechanical Engineering Northwestern Polytechnical UniversityXi’an710072People’s Republic of China School of Aeronautics and Astronautics Sichuan UniversityChengdu610065People’s Republic of China

The DD6 nickel-based superalloy exhibits remarkably high temperature properties;therefore,it is employed as a crucial structural material in the aviation ***,this material is difficult to ***-assisted drilling(UAD)combines the characteristics of vibration processing technology and conventional drilling technology,significantly improving the machinability of difficult-to-machine ***,UAD experiments were performed on micro-hole machining of DD6 superalloy in this *** effects of amplitude,frequency,spindle speed,and feed rate on thrust force,machining quality,and drill bit wear were studied;thereafter,a comparison was drawn between these effects and those of conventional drilling(CD).The experimental results reveal that the thrust force decreases with an increase in spindle speed or a decrease in feed rate for both UAD and *** can significantly reduce the thrust *** the same processing parameters,the greater the amplitude,the greater the reduction of the thrust *** surface roughness of the hole wall produced by UAD is lower than that of *** with CD,UAD reduces the burr height,improves machining accuracy,and reduces drill bit wear.

关键词： Ultrasonic assisted drilling(UAD) Thrust force machining quality Drill bit wear

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Research About the Method of Sensitivity Analysis and quality Control Based on LS-SVM

Research About the Method of Sensitivity Analysis and Qualit...

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2015年中国智能自动化学术会议

作者： Yiyong Yao Hongren Chen Liping Zhao Guangzhou Diao School of Mechanical Engineering Xi’an Jiaotong University State Key Laboratory for Manufacturing Systems Engineering Xi’an Jiaotong University

Focusing on the real-time quality control in machining process, sensitivity analysis method based on LS-SVM was proposed in this paper to control the quality of products. The relationship between machining quality and influence factors is built by LS-SVM(least squares support vector machine). Sensitivity and contribution rate are calculated in sensitivity analysis. The quality of products can be controlled by controllable factors according to the result of sensitivity analysis,and the control effect can be evaluated by quality loss function. The method verification was conducted by a simulation example. At the end of this paper, a case about globoidal cam was presented to verify the feasibility and accuracy.

关键词： LS-SVM machining quality Sensitivity analysis quality control

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