Li Fu Xu

An Experimental Study on Grinding of SiC/Al Composites

In this paper, grinding experiments on the machining of SiCp/Al composites using SiC grinding wheel have been carried out. The effect of the grinding parameters on the grinding forces, surface morphology and surface roughness were evaluated. The results indicate that the grinding depth has more significant effect on the grinding force than that of feed speed, and there are many fracture or crushed SiC particles on the ground surface. Therefore, the SiC wheels can be used for rough grinding of SiCp/Al composites.

Three-Dimensional Finite Element Simulation Analysis of Cutting Force of SiCp/Al Composite Thin-Walled Parts

In milling process, cutting force is the main cause of machining deformation, and in machining of thin-walled parts, machining deformation is the major factor for machining error. In this paper, through finite element analysis software ABAQUS, three-dimensional simulation analysis on the machining of SiCp/Al composite thin-walled parts with a polycrystalline diamond tool have been carried out. It reveals the influence of radial depth of cut, cutting speed, and feed per tooth on cutting force. Analysis results show that: higher speed, small radial depth of cut and moderate feed per tooth can effectively reduce cutting force and inhibit deformation. In addition, a comparison is made between analysis results of milling force and high accuracy milling force prediction model, results from the two methods are similar.

Experimental Study of Tool Wear during Quasi High Speed Turning Titanium Alloy with Large Cutting Depth

The wear morphology of rake face and flank face of tool is investigated by turning titanium alloy TC4 with CBN solid tool. It has been observed that the main wear form of rake face and flank face of tool is groove wear. The relation between tool flank wear and cutting speeds, feed rate, and cutting depth obtained from experimental data is given.

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

Experimental Study on Surface Quality at Different Milling Speed of High Volume Fraction SiCp/Al Thin Walled Test-Piece

In order to investigate the influence of milling velocity on surface roughness of the cutting entrance, middle part and cutting exit, high milling experiment for the thin walled test-piece of high volume fraction SiCp/Al composites was preformed with PCD tool. The results indicate that when milling at lower speed 60m/min, the SiCp/Al test-piece is apt to vibrate. As well as, the surface roughness machined test-piece in cutting exit increases obviously and its Ra value reaches 1.721μm, which leads to the inferior surface quality. In conclusion, the surface roughness, either at cutting entrance, middle or at cutting exit, all is a decline trend with the milling speed increasing. Moreover, Ra value of the cutting entrance is the biggest, followed by the middle, and the cutting exit is the smallest.

Study on Finite Element Simulation of the Influence of Cutting Speed on Chip Formation of SiCpAl Composites in High Speed Milling

Application prospect of the high volume fraction SiCp/Al composites becomes increasingly widespread, the study of cutting mechanism is important for achieving its high efficient and precision machining. In this paper, a three-dimensional beveled simulation model of high volume fraction SiCp/Al composites on high-speed milling is established by finite element software ABAQUS, the constitutive on model material, the tool-chip contact and the chip separation model is elected reasonably.The paper analyzes the effect of cutting speed on the chip formation and the stress distribution of the material. The results shows that: with the increasing of cutting speed, the chip is easily broken, cutting speed have little impact on the maximum stress of the material.

Simulation of High Speed Milling of SiCp/Al Metal Matrix Composites Based on Deform

By 3D finite element simulation for temperature field and tool wear of SiCp/Al metal matrix composites under the condition of high speed milling, we draw a conclusion that the most significant influence on cutting temperature is cutting speed, less is feed rates, the minimum is cutting depth, which is exactly the same as the influence law of ordinary metal cutting. In the course of high-speed milling SiCp/Al by PCD tools, the higher the cutting speed is, the bigger wearing depth of tools is. When v=300m/min, ap=0.5 mm, f=0.3 mm/r, the transient temperature in the milling would reach to 619°C. Such a high temperature can cause graphitizing wear of the PCD tools. Because of the effectiveness of the simulation’s conclusion, it is vital significance to the reasonable options of cutting parameters and the prolongation of tool life.

Drilling of SiCp/Al Composites with Electroplating Diamond Drills

SiCp/Al composites have been used in a number of engineering applications including the consumer goods. However, the machining of these materials is very difficult because of the abrasive characteristics of the reinforced particulates. In this paper drilling studies on SiCp/Al composites with high volume fraction and large size SiC particles have been conducted by using electroplating diamond drills, and the influences of the cutting speed on the drilling force and surface roughness were investigated.

Experimental Study on Exit Edge Defects in Two Dimension Cutting of SiCp/Al Composites

In this paper, the influence of the tool rake angle, cutting depth and cutting speed on exit edge defect sizes are discussed by the two dimension cutting experiment of SiCp/Al composites. The sizes are measured by using the Keyence VHX-1000C type super preview 3D microscopy. The results indicate that exit edge defect sizes are influenced greatly by tool rake angle and cutting depth, and are influenced slightly by the cutting speed. The edge defect sizes have an overall downward trend when the tool rake angle is smaller than 5°, and have an apparent upward trend when the tool rake angle (γ0) is 10°.The length (L), height (H) of exit edge defects and the negative shear angle increase with increasing of the cutting depth.

Analysis on Grinding Force of SiCp/Al Composites Based on MATLAB

SiCp/Al composites were grinded with Diamond Wheel on high-precision machine. Acquiring grinding force signals of the experiment with High Speed Advantech PCI－1712 board. Acquired grinding force signals are analyzed in MATLAB which has mighty function disposing signals. Through analyzing the grinding force in time field, frequency field and the signals wavelet analysis for different grinding parameters, found that the feed velocity has much more influence on the grinding force, the grinding force ratio and the standard variance of the grinding force than the depth of grinding when the velocity of the Diamond Wheel is fixed. The frequency structure and energy distribution of grinding force are showed in PSD analysis. The signals are de-noised in wavelet tools. The result of the experiment indicates the grinding force increases, the grinding force ratio decreases and the standard variance of the grinding force varies complex for different material with the increasing of the velocity of the workpiece and the grinding depth.