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A comprehensive research on wear resistance of GH4169 superalloy in longitudinal-torsional ultrasonic vibration side milling with tool wear and surface quality

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Chinese Journal of Aeronautics 2024年第4期37卷 556-573页

作者： Baoqi CHANG Zhaoxi YI Fen ZHANG Lian DUAN Ji-an DUAN School of Mechanical and Electrical Engineering Central South UniversityChangsha 410083China State Key Laboratory of High Performance and Complex Manufacturing Central South UniversityChangsha 410083China School of Physics and Electronics Central South UniversityChangsha 410083China

To improve the service and machining performance of the workpiece, the tool wear mechanisms, surface machining quality, and wear resistance in conventional side milling(CSM)and longitudinal-torsional ultrasonic vibration side milling(LTUVSM) of GH4169 superalloy at different cutting lengths are investigated systematically. tool wear mechanisms are revealed and the correlation between machined surface quality with tool wear is analyzed correspondingly. tool wear patterns mainly include adhesive wear, diffusion wear, abrasive wear, and chipping sticking.Better surface quality is achieved in LTUVSM due to a maximum reduction of flank wear bandwidth and wear rate by 71.9% and 71.5%, respectively, compared to CSM. The friction coefficient,initial wear stage time, and wear volume of dry sliding wear were measured to evaluate the workpiece wear resistance. The maximum reductions in friction coefficient and wear volume in LTUVSM are 18.2% and 15.8% compared to CSM. The regular ultrasonic vibration textures suppress the friction and the growth of contact nodes in the contact area, decreasing the degree of surface wear, which is demonstrated by a 38.8% increase in initial wear stage time compared to CSM.In conclusion, the workpiece in LTUVSM exhibits higher wear resistance because of the improvement of tool wear and the guarantee of surface quality.

关键词： Dry sliding wear Surface quality tool wear Ultrasonic vibration wear resistance

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Effects of fiber orientation on tool wear evolution and wear mechanism when cutting carbon fiber reinforced plastics

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Chinese Journal of Aeronautics 2023年第5期36卷 549-565页

作者： Weizhou WU Shipeng LI Xuda QIN Wentao LIU Xin CUI Hao LI Mengrui SHI Haibao LIU Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education Tianjin UniversityTianjin 300350China Tianjin Aerospace Long March Launch Vehicle Manufacturing Co.Ltd Tianjin 30000China Centre for Aeronautics School of AerospaceTransport and ManufacturingCranfield UniversityCranfield MK430ALUK

The aim of the present paper is to reveal the influence of different fiber orientations on the tool wear evolution and wear mechanism. Side-milling experiments with large-diameter milling tools are conducted. A finite element(FE) cutting model of carbon fiber reinforced plastics(CFRP)is established to get insight into the cutting stress status at different wear stages. The results show that different fiber orientations bring about distinct differences in the extent, profile and mechanism of tool wear. Severer wear occurs when cutting 45° and 90° plies, followed by 0°, correspondingly,the least wear is obtained when θ = 135°(θ represents the orientation of fibers). Moreover, the worn profiles of cutting tools when θ = 0° and 45° are waterfall edge, while round edge occurs whenθ = 135° and a combined shape of waterfall and round edge is obtained when θ = 90°. The wear mechanisms under different fiber orientations are strongly dependent on the cutting stress distributions. The evolution of tool wear profile is basically consistent with the stress distribution on the tool surface at different wear stages, and the extent of tool wear is determined by the magnitude of stress on the tool surface. Besides, the worn edges produce an actual negative clearance angle,which decreases the actual cutting thickness and leads to compressing and bending failure of fibers beneath the cutting region as well as low surface qualities.

关键词： Carbon fiber reinforced plastics(CFRP) Fiber orientation Finite element method(FEM) tool wear wear mechanism

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Gaussian process regression model incorporated with tool wear mechanism

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Chinese Journal of Aeronautics 2022年第10期35卷 393-400页

作者： Dehua LI Yingguang LI Changqing LIU National Key Laboratory of Science and Technology on Helicopter Transmission Nanjing University of Aeronautics and AstronauticsNanjing 210016China

Cutting tool condition directly affects machining quality and efficiency.In order to avoid severely worn tools used during machining process and fully release the remaining useful life in the meanwhile,a reliable evaluation method of remaining useful life of cutting tools is quite necessary.Due to the variation of cutting conditions,it is a challenge to predict remaining useful life of cutting tools by a unified model.In order to address this issue,this paper proposes a method for predicting the remaining useful life of cutting tools in variable cutting conditions based on Gaussian process regression model incorporated with tool wear mechanism,where the predicted value at adjacent moments is constrained to a linear relationship by the covariance matrix of Gaussian model based on the assumption of progressive tool wear process,so the wear process under continuous changing conditions can be modelled.In addition to that,the input feature space and the output of the model are also enhanced by considering the tool wear mechanism for improving prediction accuracy.Machining experiments are performed to verify the proposed method,and the results show that the proposed could improve the prediction of tool remaining useful life significantly.

关键词： Remaining useful life Cutting condition tool wear wear mechanism Gaussian process regression

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High-efficiency ultrasonic assisted drilling of CFRP/Ti stacks under non-separation type and dry conditions

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Journal of Zhejiang University-Science A(Applied Physics & Engineering) 2024年第4期25卷 275-291页

作者： Enze YING Zehua ZHOU Daxi GENG Zhenyu SHAO Zhefei SUN Yihang LIU Lianxing LIU Xinggang JIANG Deyuan ZHANG School of Mechanical Engineering and Automation Beihang UniversityBeijing 100191China Beijing Chenjing Electronics Company Limited Beijing 100015China Aerospace Times Feihong Technology Company Limited Beijing 100094China

In this study,to address the low efficiency for conventional ultrasonic-assisted drlling(UAD)of carbon fiber-reinforced plastic and titanium alloy(CFRP/Ti)stacks,feasibility experiments of non-separation UAD,in which continuous cutting between the tool and the workpiece occurs at a high feed rate,are carried out.The experimental results indicate that,compared to conventional separation UAD,the non-separation UAD effectively reduces the cutting forces by 24.2%and 1.9%for CFRP stage and 22.1%and 2.6%for the Ti stage at the feed rates of 50 and 70μm/r,respectively.Furthermore,the non-separation UAD significantly improves hole quality,including higher hole diameter accuracy,lower hole surface roughness,and less hole damage.In addition,the non-separation UAD can decrease adhesive tool wear.This study demonstrates that,compared to conventional drilling(CD),the non-separation UAD can effectively improve drilling quality and tool life while maintaining high efficiency.

关键词： Carbon fiber-reinforced plastic and titanium alloy(CFRP/Ti)stacks Ultrasonic-assisted drlling(UAD) Cutting force Surface integrity tool wear

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tool wear criterion,tool life,and surface roughness during high-speed end milling Ti-6Al-4V alloy

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Journal of Zhejiang University-Science A(Applied Physics & Engineering) 2010年第8期11卷 587-595页

作者： Song ZHANG Jian-feng LI MOE Key Laboratory of High Efficiency and Clean Mechanical Manufacture School of Mechanical Engineering Shandong University Jinan 250061 China

The objective of the present research is to investigate the relationship among tool wear, surface topography, and surface roughness when high-speed end milling Ti-6Al-4V alloy, and also to define an optimal flank wear criterion for the cutting tool to integrate tool life and the surface roughness requirements of the finish milling process. An annealed Ti-6Al-4V alloy was selected as the workpiece material, undergoing end milling with uncoated carbide inserts. The flank wear of the insert was observed and measured with the toolmaker's microscope. To examine machined surfaces, 3D surface topography was provided by the white light interferometer, and the arithmetical mean roughness (Ra) was calculated with the WYKO Vision32 software. The flank wear increases with cutting time, and the maximal flank wear is set as the flank wear criterion. As the cutting process progresses, tool wear is the predominant factor affecting the variation of surface roughness. According to the plots for the tool wear propagation and surface roughness variation, an optimal flank wear criterion can be defined which integrates the tool life and the surface roughness requirements for the finish milling process.

关键词： tool wear Surface topography Surface roughness Optimal flank wear criterion

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tool wear during high speed turning in situ TiC_p/TiB_w hybrid reinforced Ti-6Al-4V matrix composite

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Chinese Journal of Aeronautics 2016年第5期29卷 1425-1435页

作者： Ge Yingfei Xu Jiuhua Huan Haixiang School of Mechanical Engineering Nanjing Institute of Technology College of Mechanical & Electrical Engineering Nanjing University of Aeronautics & Astronautics

Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix composite （TMCs）. The combined effects of abrasive wear and diffusion wear caused the big crater on PCD and carbide tool rake face. Compared to the PCD, bigger size of crater was found on the carbide tool due to much higher cutting temperature and the violent chemical reaction between the Ti element in the workpiece and the WC in the tool. However, the marks of the abrasive wear looked much slighter or even could not be observed on the carbide tool especially when low levels of cutting parameters were used, which attributes to much lower hardness and smaller size of WC combined with more significant chemical degradation of carbide. When cutting TC4 using PCD tool, notch wear was the most significant wear pattern which was not found when cutting the TMCs. However, chipping, adhesive wear and crater wear were much milder when compared to the cutting of titanium matrix composite. Due to the absence of abrasive wear when cutting TC4, the generated titanium carbide on the PCD protected the tool from fast wear, which caused that the tool life for TC4 was 6-10 times longer than that for TMCs.

关键词： Carbide tool High speed cutting PCD tool Titanium matrix composite tool wear Turning

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tool wear and Its Effect on Surface Roughness in Diamond Cutting of Glass Soda-lime

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Chinese Journal of Mechanical Engineering 2012年第6期25卷 1224-1230页

作者： JIA Peng ZHOU Ming Changchun Institute of Optics Fine Mechanics and Physics Chinese Academy of Sciences Changchun 130033 China School of Mechanical and Electrical Engineering Harbin Institute of Technology Harbin 150001 China

For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Many researches on diamond tool wear in glass cutting rest on wear phenomenon describing simply without analyzing the genesis of wear phenomenon and interpreting the formation process of tool wear in mechanics. For in depth understanding of the tool wear and its effect on surface roughness in diamond cutting of glass, experiments of diamond turning with cutting distance increasing gradually are carried out on soda-lime glass. The wear morphology of rake face and flank face, the corresponding surface features of workpiece and the surface roughness, and the material compositions of flank wear area are detected. Experimental results indicate that the flank wear is predominant in diamond cutting glass and the flank wear land is characterized by micro-grooves, some smooth crater on the rake face is also seen. The surface roughness begins to increase rapidly, when the cutting mode changes from ductile to brittle for the aggravation of tool wear with the cutting distance over 150 m. The main mechanisms of inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear. The proposed research makes analysis and research from wear mechanism on the tool wear and its effect on surface roughness in diamond cutting of glass, and provides theoretical basis for minimizing the tool wear in diamond cutting brittle materials, such as optical glass.

关键词： diamond cutting tool wear surface roughness soda-lime glass

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tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

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Advances in Manufacturing 2020年第2期8卷 252-264页

作者： Xiao-Fen Liu Wen-Hu Wang Rui-Song Jiang Yi-Feng Xiong Kun-Yang Lin School of Mechanical Engineering Northwestern Polytechnical UniversityXi'an 710072People's Republic of China School of Aeronautics and Astronautics Sichuan UniversityChengdu 610065People's Republic of China

The in-situ TiB2 particle reinforced aluminum matrix composites are materials that are difficult to machine,owing to hard ceramic particles in the matrix.In the milling process,the polycrystalline diamond(PCD)tools are used for machining these materials instead of carbide cutting tools,which significantly increase the machining cost.In this study,ultrasonic vibration method was applied for milling in-situ TiB2/7050A1 metal matrix composites using a TiAIN coated carbide end milling tool.To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling(UAM),the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail.Additionally,a comparative experimental study with and without ultrasonic vibration was carried out to investigate the infuences of ultrasonic vibration and cutting parameters on the cutting force,tool life and tool wear mechanism.The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period,in ultrasonic vibration assisted cutting.I arge instantaneous acceleration can be obtained in axial ultrasonic vibration milling.The cutting force in axial direction is significantly reduced by 42%-57%,40%--57%and 44%-54%,at different cutting speeds,feed rates and cutting depths,respectively,compared with that in conventional milling.Additionally,the tool life is prolonged approximately 2--5 times when the ultrasonic vibration method is applied.The tool wear pattern microcracks are only found in UAM.These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB2/7050A1 metal matrix composites.

关键词： Aluminum matrix composites Ultrasonic vibration Milling Cutting force tool wear

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tool wear condition monitoring method of five-axis machining center based on PSO-CNN

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Mechanical Engineering Science 2022年第2期4卷 11-20,I0006页

作者： Shuo WANG Zhenliang YU Changguo LU Jingbo WANG Yingkou Institute of Technology School of Mechanical and Power EngineeringYingkouChina

The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency,so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status.Firstly,the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology,and the features related to the tool wear status are extracted in the time domain,frequency domain and time-frequency domain to form a feature sample matrix;secondly,the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types:slight wear,normal wear and sharp wear to construct a target Finally,the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status.The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%;and compared with BP model,CNN model and SVM model,the accuracy indexes are improved by 9.48%,3.44%and 1.72%respectively,which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.

关键词： five-axis machining center tool wear PSO-CNN intelligent monitoring

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Hardening Effect on Machined Surface for Precise Hard Cutting Process with Consideration of tool wear

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Chinese Journal of Mechanical Engineering 2014年第6期27卷 1249-1256页

作者： YUE Caixu LIU Xianli MA Jing LIU Zhaojing LIU Fei YANG Yongheng State Engineering Laboratory of High Efficiency Cutting and tool Harbin University of Science and Technology

During hard cutting process there is severe thermodynamic coupling effect between cutting tool and workpiece, which causes quenching effect on finished surfaces under certain conditions. However, material phase transformation mechanism of heat treatment in cutting process is different from the one in traditional process, which leads to changes of the formation mechanism of damaged layer on machined workpiece surface. This paper researches on the generation mechanism of damaged layer on machined surface in the process of PCBN tool hard cutting hardened steel Cr12MoV. Rules of temperature change on machined surface and subsurface are got by means of finite element simulation. In phase transformation temperature experiments rapid transformation instrument is employed, and the effect of quenching under cutting conditions on generation of damaged layer is revealed. Based on that, the phase transformation points of temperature under cutting conditions are determined. By experiment, the effects of cutting speed and tool wear on white layer thickness in damaged layer are revealed. The temperature distribution law of third deformation zone is got by establishing the numerical prediction model, and thickness of white layer in damaged layer is predicted, taking the tool wear effect into consideration. The experimental results show that the model prediction is accurate, and the establishment of prediction model provides a reference for wise selection of parameters in precise hard cutting process. For the machining process with high demanding on surface integrity, the generation of damaged layer on machined surface can be controlled precisely by using the prediction model.

关键词： precise hard cutting hardened mould steel hardening effect damaged layer on machined surface tool wear

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