A Systematic Study on the Effects of Process Parameters on Spinning of Thin-Walled Curved Surface Parts With 2195 Al-Li Alloy Tailor Welded Blanks Produced by FSW

The manufacturing process is inevitably accompanied with the production of scraps, which leads to resource waste and environmental pollution. Recycling and remanufacturing are the most commonly used approaches for metal scraps due to their well-established advantages from economic and environmental perspectives. In this study, spinning experiments with 2195 Al-Li alloy tailor welded blanks produced by friction stir welding from metal scraps were conducted under different process parameter designs. And then the effects of various process parameters on spinning of thin-walled curved surface parts were systematically studied. The results of the corresponding experimental groups show that the roller attack angle, the spinning clearance, and the installation method of tailor welded blanks have the most significant effect on the weld torsion angle. In addition, it was found that along the longitude direction of spun parts, the surface roughnesses of the weld of spun parts were greatly improved under the roller nose radius of 10 mm, the spinning clearance of 1.0 mm, the constant linear velocity, and the installation method of tailor welded blanks (the lower surface of tailor welded blanks is spun by rollers), while the process parameters have little significant effect on the surface roughness along the latitude direction of spun parts. Furthermore, it can be concluded that the forming profiles of spun parts fitted the mandrel well under the roller nose radius of 6 mm, double rollers, the roller attack angle of 30° and 45°, spinning clearance of 1.5 mm, and the installation method of tailor welded blanks (the upper surface of tailor welded blanks is spun by rollers). The research results will provide guidance for the precise spinning of thin-walled curved surface parts with tailor welded blanks. Thereby, it is also beneficial for green manufacturing involving recycling and remanufacturing of metal scraps.

Process path planning based on efficiency model for ultrasonic cutting curved surface of honeycomb composite parts

According to the roughing chip shape, the ultrasonic vibration cutting honeycomb material curved surface parts are divided into two rough machining processes of “V” shape cutting and rectangular cutting. Based on the non-interference characteristic cutter location counting model, the cutting efficiency model is established to select a better process. First, the residual height model of the two processes is established, and the residual height is controlled by longitudinal and lateral lifting the cutter location. Second, using the coordinate system conversion principle, the projection method is used to perform global interference check on the triangular-blade and the disk-blade which are used for ultrasonic cutting honeycomb composite, and then the characteristic cutter location generation method for changing the swing angle to avoid interference is proposed. Finally, a cutting efficiency model is established. Process analysis of case parts shows: when the feed rate of disk-blade is less 0.6 times to that of triangular-blade, the machining efficiency of “V” shape cutting is higher than that of rectangular cutting. When the disk-blade’s feed rate approaches or exceeds the triangular-blade’s, especially under this circumstance that the large parts is cut, the efficiency of the latter is higher.

Influence of spindle speed on tool wear in high-speed milling of Inconel 718 curved surface parts

High-speed milling, which provides an efficient approach for high-quality machining, is widely adopted for machining difficult-to-machine materials such as Inconel 718. For high-speed milling of Inconel 718 curved surface parts, the spindle speed which determines cutting speed directly is regarded as an important cutting parameter related to tool wear and machining efficiency. Meanwhile, because of the changing geometric features of curved surface, cutting force is changing all the time with the variation of geometric features, which influences not only tool wear but also machining quality significantly. In this study, the influence of spindle speed on coated tool wear in high-speed milling of Inconel 718 curved surface parts is studied through a series of experiments on considering tool life, cutting force, cutting force fluctuation, and machining efficiency. According to the experimental results, the appropriate spindle speed that can balance both the tool life and the machining efficiency is selected as 10,000 r/min for high-speed milling of Inconel 718 curved surface parts. In addition, the coated tool wear mechanism is investigated through scanning electron microscopy–energy dispersive x-ray spectroscopy analysis. The results show that at the beginning wear stage and the stable wear stage, the coated tool wear is mainly caused by mechanical wear. Then, with the increasing cutting temperature due to the blunt tool edge, the tool wear becomes compound wear which contains more than one wear form so as to cause a severe tool wear.

Comparison of Curved Surface Part Finishing Simulation Based on CAXA

Choosing five kinds of curved surface finishing methods is commonly used in CAXA and processing compared to the same curved surface parts, on the premise of making the parts same residual height and exploring their selection principle.

Five-Axis Machining Method of Complicated Curved Surface

Five-axis CNC machine tools are constituted by three-axis machine tools and two rotational degrees of freedom. Using the two rotary axes, five-axis CNC machine tools can improve the accessibility and become an important means of machining complex surface parts. In order to get high tapered complicated curved surface parts, a dual turntable five-axis machine with A-C tables was introduced and the mathematical models of the CNC processing of the workpiece were established. Through machining experiment of the several major processed forms, it shows that the dual turntable five-axis machine system has high machining quality and could be used to machine the difficult-to-cut materials, spatial complicated curved surface parts and special requirements.

Reverse Modeling of Vehicle Suspension Control Arm

Reverse modeling of vehicle suspension control arm is studied. Firstly, the data of vehicle suspension control arm is acquired. Secondly, the scanning point cloud data is processed. Then 3D model of vehicle suspension control arm is reconstructed. Finally, models deviation is analyzed to find out the deficiencies and to improve the accuracy of the model. Reverse modeling based on CATIA can make up the shortage of traditional modeling method and solve the problem of gaining the data of complex curved surface parts. It also can shorten the innovation and improvement cycle of the vehicle suspension control arm and reduce the production cost and enhance enterprise competitiveness.