An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts
Abstract
:1. Introduction
2. Materials and Methods
2.1. Characterization of the Machined Parts
2.2. Schematic of the Test Stand
2.3. Schematic of the Electro-Contact Heating Control System
3. Results and Discussion
3.1. Effect of Machining Type and Machining Parameters on the Cutting Operation
3.1.1. Effect of Cutting Forces
3.1.2. Effect of Cutting Parameters on Temperature Growth
3.1.3. Effect of Heating Current Density and Turning Parameters on Changes in Cutting Forces
3.2. Use of the Electro-Contact Heating Control System
4. Conclusions
- Cutting forces:
- -
- cutting forces generated during turning and boring increase from 2.6 to 3.7 times with considerable pulsation at the beginning of machining. This is caused by an increase in the depth of cut, and the pulsation of cutting forces in the initial stage of machining is a function of workpiece runout and the depth of cut; on the other hand, increasing the temperature improves the machinability of the materials as it leads to a reduction in their strength characteristics and a significant increase in the shape stability coefficient; increasing the temperature improves the machinability of Grade 2 and Ti-64, as their strength characteristics decrease, and significantly increases the shape stability coefficient;
- -
- the main cutting forces and the thrust cutting force generated during the machining of metal-ceramic titanium are from 25 to 27% and from 22 to 25% lower, respectively, than for uniform titanium;
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- the cutting forces during the boring of Ti-64 increase from 1.5 to 1.7 times, which leads to an increase in the intensity of the technological field of ultimate stresses, the relaxation of which leads to large deformations of the thin-walled sleeves.
- Effect of cutting parameters on temperature growth:
- -
- depth of cut at f = const has practically no effect on the machining temperature;
- -
- increasing feed rate f from 0.12 to 0.212 mm/rev leads to an increase in temperature by 35–420 °C;
- -
- changes in cutting speed (at f = const, ap = const) in the range from 1.3 to 3.0 m/s cause an increase in the average cutting zone temperature by 15–18 °C.
- Effect of current density on changes in cutting forces generated during the turning of Grade 2:
- -
- main cutting force Fc, at Ig.opt = 470 A/(m2·10−6) and θ°skr = 900 °C, declines by 18–22%;
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- feed component f decreases in the range from 13 to 15%;
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- a further increase in current density leads to an intensification of flank wear and an increase in the cutting forces and the temperature in the cutting zone.
- Effect of cutting parameters on changes in cutting forces in the operation of turning Ti-64:
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- increasing the feed rate leads to a change in the slope of the Ff = (f, Ig) curve, at vc = const, ap = const, causing practically no decrease in the Fc = (f, Ig) curve;
- -
- increasing the depth of cut ap causes practically no decrease in the Ff c = (f, Ig) curve, at vc = const, f = const, which is associated with the weak effect of ap on cutting temperature.
- The application of the electro-contact heating control system allows machining conical parts and semi-finished products at lower cutting forces. It also leads to an increase in the deformation of the thin-walled casings caused by the runout of the workpiece. Additionally, it was found that the dimensions of harder parts stabilize better (compared to parts with a lower hardness).
5. Patents
- Lathe tailstock [patent no. 212961]/Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko. Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko.-Patent no.; Patent application no.//Official Gazette of the Patent Office, 2012, No. 12, p. 2897.
- Lathe tailstock [patent no. 211537]/Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko; author: Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko.-Patent no.; Patent application no.//Official Gazette of the Patent Office, 2012, No. 5, p. 1073.
- Lathe tailstock [patent no. 213606]/Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko, Jakub Szabelski; author: Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko, Jakub Szabelski.-Patent no.; Patent application no.//Official Gazette of the Patent Office, 2013, No. 4, p. 851.
- Lathe tailstock [patent no. 214058]/Victor Taranenko, Antoni Świć, Dariusz Wołos, Georgiy Taranenko, Jakub Szabelski; author: Victor Taranenko, Antoni Świć, Dariusz Wołos, Gieorgij Taranenko, Jakub Szabelski.-Patent no.; Patent application no.//Official Gazette of the Patent Office, 2013, No. 6, p. 1426.1.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature
H | external height of the machined cylindrical surface |
h | internal height of the machined cylindrical surface |
D | external diameter of the machined cylindrical surface |
d | internal diameter of the machined cylindrical surface |
HV | material hardness according to Vickers scale |
σb | tensile strength [MPa] |
vc | cutting speed |
f | feed rate |
ap | depth of cut |
θ | temperature |
F | cutting force |
ρ | electrical resistance |
γ | rake angle |
α | clearance angle |
κr | cutting edge angle |
κp’ | end cutting edge angle |
λs | side cutting edge inclination angle |
rp | nose radius |
Kk | shape stability coefficient |
Fc | cutting force |
Fp | thrust force |
Ff | feed force |
hp | flank wear |
Fn | cross-sectional surface of the machined layer |
Ig.op. | optimal current density |
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Cutting Forces F, [N] | Turning | Boring | ||
---|---|---|---|---|
Groove-Turning | Stabilization | Groove-Turning | Stabilization | |
Ff | 145 | 380 | 145 | _ |
Fp | _ | _ | _ | 480 |
Fc | 150 | 490 | 150 | 600 |
Material | Physicomechanical Properties of Materials at Q = 20–1000 °C | |||||||
---|---|---|---|---|---|---|---|---|
HV | σb | ρ · 10−8 Ω·m | Kk | |||||
20° | 1000° | 20° | 1000° | 20° | 1000° | 20° | 1000° | |
H30 | 1450 | 380 | − | _ | 18.6 | 96 | 11 | 1 |
Grade 2 | _ | _ | 56 | 3 | 150 | 220 | 6 | 43 |
Ti-64 | _ | _ | 50 | 3 | _ | _ | 4 | 39 |
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Świć, A.; Gola, A.; Orynycz, O.; Tucki, K. An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts. Materials 2021, 14, 4427. https://doi.org/10.3390/ma14164427
Świć A, Gola A, Orynycz O, Tucki K. An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts. Materials. 2021; 14(16):4427. https://doi.org/10.3390/ma14164427
Chicago/Turabian StyleŚwić, Antoni, Arkadiusz Gola, Olga Orynycz, and Karol Tucki. 2021. "An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts" Materials 14, no. 16: 4427. https://doi.org/10.3390/ma14164427
APA StyleŚwić, A., Gola, A., Orynycz, O., & Tucki, K. (2021). An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts. Materials, 14(16), 4427. https://doi.org/10.3390/ma14164427