Shu Tao Huang

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.

Experimental Study of Grinding Characteristics on SiCp/Al Composites

This paper deals with the grinding performances of SiCp/Al composites with higher volume fraction and larger SiC particle. The effects of the grinding parameters on the grinding force, removal mechanisms of SiC particles have been investigated. The grinding tests were carried out by using diamond wheel on surface grinding machine. The results indicate that the feed speed of worktable has more significant effect on the grinding forces than that of grinding depth. The scanning electron microscopic images of the machined surfaces indicate that the material removal of SiC particles was primarily due to the failure of the interface between the reinforcement and matrix, and resulting from microcracks along the interface and many fracture or crushed SiC particles on the ground surface.

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.

Finite Element Simulation of Temperature Field during Grinding of SiCp/Al Composites

Based on the theory of grinding temperature field and the grinding forces obtained from the experiment, the heat flow during grinding of SiCp/Al composites was calculated. The temperature distributions have been simulated during grinding process in the case of diamond wheel and SiC wheel. The effects of grinding wheel, workpiece speed and grinding depth on the grinding temperature field were discussed. The results show that the grinding temperature with SiC wheel is much higher than that of diamond wheel in the same grinding condition, and the grinding temperature gradually decreases with the increasing of the workpiece speed or the decreasing of the grinding depth for both the diamond wheel and SiC wheel.

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.

Finite Element Simulation Research on a Large Cutting Depth and Quasi-High Speeds 3-D Milling of Titanium Alloys

In this paper, based on finite element software DEFORM, the model of a large cutting depth and quasi-high speeds milling of titanium alloys is built to study the cutting temperature and cutting force variation along with the change of cutting parameters. The simulation results show that: the location of the maximum cutting temperature appears in the cutting edges of the tool nose circular profile. Meanwhile, due to workpiece material rebound in the cutting process, the interface between workpiece and tool flank face occurs serious extrusion, which results in relatively high cutting temperature on the workpiece machined surface. In addition, cutting speed and feed rate per tooth play a key role in influencing the cutting temperature. However, the influence of cutting depth on the cutting temperature is less clear. With the increase in the feed rate and depth of cut, cutting force increased significantly. In particular, within the scope of the cutting speeds under the given conditions, the cutting force has a tendency to decrease with the cutting speed increasing over 120m/min.

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.

The Design and Finite Element Simulation Analysis of the Tool in Milling Titanium Alloys

In this paper, considering material properties and processing characteristics of titanium alloys, the milling tool under the machining condition of large cutting depth and quasi-high speed is designed, and the face milling cutter with integral CBN inserts is developed. Then, the solid model of the CBN face-milling cutter is built by the three-dimensional modeling software Pro/E. At the same time, based on the platform of finite element simulation analysis, the deformation and stress analysis of the overall structures are carried out. It turns out that: the maximum stress of the cutter blades is not in the cutter tip region but distributed approximately along the direction of the main cutting edge, the maximum stress of the tool body is at the bottom of the groove for insert. The maximum stress acting on the wedge is at the bottom of the contact area between the wedge and the cutter body. Strength sensitive area of the clamping screw happens in the connection root. Through the static analysis, the reasonableness of structural design of the tool is evaluated theoretically.