scholarly journals Cutting Performance of Randomly Distributed Active Abrasive Grains in Gear Honing Process

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1119
Author(s):  
Yang Gao ◽  
Fuwei Wang ◽  
Yuan Liang ◽  
Jiang Han ◽  
Jie Su ◽  
...  
Keyword(s):  
Removal Efficiency ◽  
Material Removal ◽  
Random Distribution ◽  
Cutting Performance ◽  
Tooth Surface ◽  
Machining Performance ◽  
Abrasive Grains ◽  
Gear Honing ◽  
First Contact ◽  
Cutting Model

In power gear honing, the random distribution of abrasive grains on the tooth surface of the honing wheel is the main factor that influences the machining performance of high-quality hardened gears. In order to investigate the micro-edge cutting performance of the active abrasive grains on the workpiece gear, the real honing process is simplified into a micro-edge cutting model with random distribution of active abrasive grains in the cells of the meshing area by obtaining the random distribution states such as the position, orientation and quantity of the honing wheel teeth. The results show that although the active abrasive grains are distributed at different locations, they all experience three types of material removal—slip rubbing, plowing and cutting—allowing the gear honing process to have the combined machining characteristics of grinding, lapping and polishing. The active abrasive grains in first contact produce high honing force, high material removal efficiency and poor surface roughness on the machined workpiece, while the latter ones have the opposite effects. The dislocation angle affects the chip shape and chip discharging direction, and the highest honing force and material removal efficiency is achieved with a dislocation angle of 135°. The higher the number of active abrasive grains in a given contact area, the higher the material removal efficiency.

Effect of Cutter Performance on Finished Tooth Form in Gear Shaving

1992 ◽  
Author(s):  
I. Moriwaki ◽  
M. Fujita
Keyword(s):  
Computer Simulation ◽  
Mean Value ◽  
Cutting Performance ◽  
Simulation Program ◽  
Tooth Surface ◽  
Depth Of Cut ◽  
Small Depth ◽  
Computer Simulation Program ◽  
Tooth Form ◽  
Cutting Model

Abstract The authors have been developed a computer simulation program of gear shaving. In the present paper, a new cutting model of shaving process is proposed so as to incorporate an effect of a cutting performance of shaving cutter into the simulation program. In this cutting model, it is assumed that a tooth flank material of work gear can be removed only when a depth of cut of a cutting edge exceeds a certain criterion. It is also assumed that the criterion have no definite value but has the nominal distribution over the tooth surface. The mean value of the distribution can define a characteristic of cutting performance of shaving cutter. The small mean value means that even small depth of cut can cause a stock removal; i.e. a good cutter performance. The computer simulations on gear shaving are performed to reveal the effect of the cutter performance on shaved tooth form. Under the conditions used in these simulations, the pressure angle error on the shaved tooth profile becomes remarkable as the cutter performance becomes worse. Thus, the developed computer simulation program of gear shaving has a reliability on the prediction of shaved tooth form. It will be useful for design of shaving cutter, judgement of tool life, and so on.

High-Throughput Picosecond Laser Machining of Aerospace Nickel Superalloy

2021 ◽  
pp. 095440542110288
Author(s):  
Sundar Marimuthu ◽  
Bethan Smith
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Thermal Damage ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Nickel Superalloy ◽  
Laser Machining ◽  
Process Conditions ◽  
Machining Performance

This manuscript discusses the experimental results on 300 W picosecond laser machining of aerospace-grade nickel superalloy. The effect of the laser’s energetic and beam scanning parameters on the machining performance has been studied in detail. The machining performance has been investigated in terms of surface roughness, sub-surface thermal damage, and material removal rate. At optimal process conditions, a picosecond laser with an average power output of 300 W can be used to achieve a material removal rate (MRR) of ∼140 mm3/min, with thermal damage less than 20 µm. Shorter laser pulse widths increase the material removal rate and reduce the resultant surface roughness. High scanning speeds improve the picosecond laser machining performance. Edge wall taper of ∼10° was observed over all the picosecond laser machined slots. The investigation demonstrates that high-power picosecond lasers can be used for the macro-machining of industrial components at an acceptable speed and quality.

Methodology for Evaluation of Treated Steels and Alloys in Abrasive Processing

2021 ◽  
Vol 410 ◽  
pp. 262-268
Author(s):  
Vyacheslav M. Shumyacher ◽  
Sergey A. Kryukov ◽  
Natal'ya V. Baidakova
Keyword(s):  
Physical And Mechanical Properties ◽  
Metals And Alloys ◽  
Grinding Wheel ◽  
Measuring Instruments ◽  
Abrasive Machining ◽  
Machining Performance ◽  
Abrasive Grains ◽  
Abrasive Tools ◽  
Composition Structure ◽  
Grinding Operations

One of the critical physical and mechanical properties of metals and alloys is the suitability for abrasive machining. Machining by abrasive tools is the final operation that sets the desired macro-geometry parameters of processed blanks and microgeometry parameters of processed surfaces such as roughness and length of a bearing surface. Abrasive machining determines the most important physical and mechanical parameters of a blank surface layer, i.e. stresses, phase composition, structure. Machinability by abrasive tools depends on the machining performance affected both by the blank material properties and various processing factors. In our previous studies, we proved that during abrasive machining the metal microvolume affected by abrasive grains accumulates energy. This energy is used for metal dispersion and is converted into heat. According to the theoretical studies described herein, one may note the absence of a reliable and scientifically valid method as well as measuring instruments to determine the machinability of metals and alloys by abrasive tools. For this reason, we suggested a method simulating the effect the multiple abrasive grains produce in a grinding wheel, and enabling us to identify machinability of metals and alloys, select the most efficient abrasive materials for machining of the same, and form the basis for development of effective grinding operations.

scholarly journals Performance Evaluation and Comparison between Direct and Chemical-Assisted Picosecond Laser Micro-Trepanning of Single Crystalline Silicon

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 41 ◽  
Author(s):  
Hao Zhu ◽  
Zhaoyang Zhang ◽  
Kun Xu ◽  
Jinlei Xu ◽  
Shuaijie Zhu ◽  
...  
Keyword(s):  
Material Removal ◽  
Crystalline Silicon ◽  
Removal Rate ◽  
Picosecond Laser ◽  
Orthogonal Experimental Design ◽  
Single Crystalline Silicon ◽  
Machining Performance ◽  
Single Crystalline ◽  
Direct Laser ◽  
Micro Holes

The fabrication of micro-holes in silicon substrates that have a proper taper, higher depth-to-diameter ratio, and better surface quality has been attracting intense interest for a long time due to its importance in the semiconductor and MEMS (Micro-Electro-Mechanical System) industry. In this paper, an experimental investigation of the machining performance of the direct and chemical-assisted picosecond laser trepanning of single crystalline silicon is conducted, with a view to assess the two machining methods. The relevant parameters affecting the trepanning process are considered, employing the orthogonal experimental design scheme. It is found that the direct laser trepanning results are associated with evident thermal defects, while the chemical-assisted method is capable of machining micro-holes with negligible thermal damage. Range analysis is then carried out, and the effects of the processing parameters on the hole characteristics are amply discussed to obtain the recommended parameters. Finally, the material removal mechanisms that are involved in the two machining methods are adequately analyzed. For the chemical-assisted trepanning case, the enhanced material removal rate may be attributed to the serious mechanical effects caused by the liquid-confined plasma and cavitation bubbles, and the chemical etching effect provided by NaOH solution.

Machining Feasibility of a New Developed Medium in Electrical Discharge Machining

2015 ◽  
Vol 656-657 ◽  
pp. 335-340 ◽  
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Hsin Min Lee ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Environmentally Friendly ◽  
Industrial Applications ◽  
Deionized Water ◽  
Machining Parameters ◽  
Machining Performance ◽  
Machining Characteristics

The environment issue and green machining technique have been induced intensive attention in recent years. It is urgently need to develop a new kind dielectric to meet the requirements for industrial applications. The aim of this study is to develop a novel dielectric using gas media immersed in deionized water for electrical discharge machining (EDM). The developed machining medium for EDM can fulfill the environmentally friendly issue and satisfy the demand of high machining performance. The experiments were conducted by this developed medium to investigate the effects of machining parameters on machining characteristics in terms of material removal rate (MRR) and surface roughness. The developed EDM medium revealed the potential to obtain a stabilizing progress with excellent machining performance and environmentally friendly feature.

Study on Analysis of Cutting Mechanism of Ball End Mill for Concave and Convex Spherical Surface Using 3D-CAD

2017 ◽  
Vol 749 ◽  
pp. 136-140
Author(s):  
Tsuyoshi Fujita ◽  
Ryota Kuromi ◽  
Hiroshi Usuki ◽  
Masahiro Hagino
Keyword(s):  
Tool Path ◽  
Spherical Surface ◽  
Cutting Performance ◽  
End Mill ◽  
Cutting Mechanism ◽  
Ball End Mill ◽  
3D Cad ◽  
Feed Direction ◽  
High Efficient ◽  
Cutting Model

In this paper, cutting mechanism and cutting performance of ball end mill for spherical surface with contour path method is investigated. Ball end mills are used to produce molds, dies and so on. However, the edge shape is complex, so cutting process is not clear. Then, it is not clear effectively using method of the tool based on good cutting performance. Therefore, in this study, the purpose is proposal of high efficient and high accurate cutting method is using 5-axis control machine tool. At first, cutting model assembled by a ball end mill (R8 mm) and a workpiece with convex or concave spherical surface (Workpiece radius 20 mm) is carried out using 3D-CAD (SolidWorks). The pick feed direction which is from bottom to top is defined “Stepped up”, the one which is inverse direction is defined “Stepped down”. In addition, both cutting methods include up milling and down milling, then there are four cutting modes. The radius of tool path for contour path are varied from 14.0 mm to 19.4 mm for convex spherical surface, from 6.5 to 9.2 mm for concave spherical surface. The lead angle of the tool is defined the plus sign when the tool is inclined to the tool feed direction and varied from-45° to 45°. Secondly, the cutting cross-sectional area is calculated by the interference of a rake surface of the tool and an uncut chip volume which can be removed by one cutting operation. Thirdly, cutting experiments are done in order to measure cutting force. Finally, analytical and experimental results are discussed, and then the cutting conditions which are expected good cutting performance are considered.

scholarly journals Investigation of the Material Removal Efficiency During Femtosecond Laser Machining

Procedia CIRP ◽  
2012 ◽  
Vol 3 ◽  
pp. 471-476 ◽  
Author(s):  
P. Stavropoulos ◽  
K. Efthymiou ◽  
G. Chryssolouris
Keyword(s):  
Femtosecond Laser ◽  
Removal Efficiency ◽  
Material Removal ◽  
Laser Machining

scholarly journals Slicing Ceramics on Material Removed by a Single Abrasive Particle

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4324
Author(s):  
Yao-Yang Tsai ◽  
Ming-Chang Wu ◽  
Yunn-Shiuan Liao ◽  
Chung-Chen Tsao ◽  
Chun-Yao Hsu
Keyword(s):  
Mathematical Model ◽  
Plastic Deformation ◽  
Brittle Fracture ◽  
Material Removal ◽  
Equations Of Motion ◽  
Abrasive Particle ◽  
Brittle Materials ◽  
Machining Parameters ◽  
Wire Saw ◽  
Cutting Model

Multi-wire saw machining (MWSM) used for slicing hard-brittle materials in the semiconductor and photovoltaic industries is an important and efficient material removal process that uses free abrasives. The cutting model of single-wire saw machining (SWSM) is the basis of MWSM. The material removal mechanism of SWSM is more easily understood than MWSM. A mathematical model (includes brittle fracture and plastic deformation) is presented in this paper for SWSM ceramic with abrasives. This paper determines the effect of various machining parameters on the removal of hard-brittle materials. For brittle fracture of SWSM ceramics, the minimum strain energy density is used as a fracture criterion. For plastic deformation of SWSM ceramics, the material removal is calculated using equations of motion. Actual wire-sawing experiments are conducted to verify the results of the developed mathematical model. The theoretical results agree with experimental data and practical experience. From the developed mathematical model, brittle fracture plays a major role in material removal of SWSM ceramics. Wire speed (S) and working load (P) are positively correlated with material removal of SWSM ceramics. The coefficient of friction is low, a lateral crack, which propagates almost parallel to the working surface, leads to more brittle fracture and material removal is increased.

scholarly journals Influence of technological system’s rigidity on the dynamics of grinding process of flexible parts

2018 ◽  
Vol 226 ◽  
pp. 02002
Author(s):  
Sergey A. Voronov ◽  
Igor A. Kiselev ◽  
Weidong Ma
Keyword(s):  
Surface Quality ◽  
Random Distribution ◽  
Turbine Blades ◽  
Grinding Process ◽  
Geometric Characteristics ◽  
Abrasive Grains ◽  
Flexible Parts

The object of the present study is to investigate the dynamic of plane grinding by the tool with random distribution of abrasive grains, owning random geometric characteristics. The model is based on the consideration of machining system’s dynamical deformable characteristics, which have influence on the workpiece’s displacement under grinding process. The excitation of vibrations has significant effects on precision and surface quality, which is especially important in machining spatial parts, such as turbine blades.

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