Investigation of sequential cryogenic hard turning and ball burnishing processes

This paper presents a sequential machining process which incorporates CBN hard turning with cryogenic pre-cooling of the workpiece (CHT) and ball burnishing (BB). The main goal of this study was to select machining conditions enhancing the quality of parts machined by hard turning including the surface roughness Ra of about 0,2 μm, good bearing properties and reducing the white layer. Changes of surface roughness, surface texture, microstructure alterations and micro-hardness distribution are discusses

Modelling of the crystallization front – particles interactions in ZnAl/(SiC)p composites

The presented work focuses on solid particle interactions with the moving crystallization front during a solidification of the metal matrix composite. The current analyses were made for silicon carbide particles and ZnAl alloy with different additions of aluminium. It was found, that the chemical composition of the metal matrix influences the behaviour of SiC particles. At the same time calculations of the forces acting on a single particle near the crystallization front were performed. For each alloy type the critical conditions that determine whether particle will be absorbed or pushed, were specified

Investigation of the machining process of spheroidal cast iron using cubic boron nitride (CBN) tools

This paper presents the experimental results of the turning of spheroidal iron (EN-GJS-500-7 grade) using L-CBN tools. The cutting process can be classified as a High Performance Cutting (HPC) due to a relatively high material removal rate of about 190 cm3/min. The investigations performed include fundamental process quantities and machined surface characteristics, i.e. componential cutting forces, specific cutting energy, average and maximum values of cutting temperature as well as temperature distribution in the cutting zone, tool wear progress visualized by appropriate wear curves and 2D/3D surface roughness parameters

Determination of substrate log-normal distribution in the AZ91/SICP composite

The aim in this work is to develop a log-normal distribution of heterogeneous nucleation substrates for the composite based on AZ91 alloy reinforced by SiC particles. The computational algorithm allowing the restore of the nucleation substrates distribution was used. The experiment was performed for the AZ91 alloy containing 1 % wt. of SiC particles. Obtained from experiment, the grains density of magnesium primary phase and supercooling were used to algorithm as input data

Influence of grinding conditions on the topographic characteristic of machined surfaces

This paper compares the ability of grinding processes to enhance functional properties of the surface textures produced. The main objective of such a comparison is to facilitate the decision about precision grinding operations. The experimental study performed includes two grinding operations using electro-corundum Al2O3 and CBN wheels. For this purpose, the topographic features of ground surfaces with the Sa roughness parameter of about 0.2?m were compared. Apart from the set of 3D roughness parameters, the frequency, fractal, wavelet and motif characteristics were analyzed

Analiza topografii powierzchni utwardzonej stali stopowej metodami analizy fraktalnej i częstotliwościowej po różnych sposobach obróbki

The paper presents an original approach to the characterization of the surface profiles/surface topographies produced on hardened steel parts using CBN tools. The experimental investigations involve recording of surface profiles and surface topographies for three different machining operations, namely hard turning, ball burnishing and superfinish in order to obtain a comparable value of the Sa (Ra) parameter of 0.2 μm. Both fractal and frequency analysis were performed in order to obtain the fractal dimension (Sfd) and the signal amplitude and the wavelength which were estimated from the power spectral density (PSD) spectra. The correlations between the Sz (Sa) roughness parameter and the fractal dimension were documented as well as appropriate relations with the frequency characteristics. In particular, the multi-fractal approach to the complex machined surfaces was discussed.W artykule przedstawiono opracowane nowe podejście do charakterystyki profili powierzchni/topografii powierzchni hartowanych stalowych elementów maszyn obrabianych przy użyciu narzędzi CBN. Badania eksperymentalne obejmowały określenie profili powierzchni i topografii powierzchni dla trzech różnych operacji obróbki – toczenia na twardo, nagniatania i dogładzania oscylacyjnego w celu uzyskania porównywalnej wartości parametru Sa (Ra) – 0,2 μm. Analizę fraktalną i częstotliwościową prowadzono dla ustalenia wymiaru fraktalnego (Sfd) oraz amplitudy sygnału i długości fali. Zostały oszacowane na podstawie gęstości widmowej mocy (PSD). Określono korelację pomiędzy parametrem chropowatości Sz (Sa) i wymiarem fraktalnym. Także ustalono ich zależności od charakterystyk częstotliwości. W szczególności uwzględniono w prowadzonej analizie multifraktalne podejście dla powierzchni złożonych

Modelowanie tarcia w skrawaniu metali ze zintegrowanym wpływem zużycia narzędzia

In this paper, friction in longitudinal turning operations when using chamfered uncoated ceramic tools is investigated. Both tool-chip and workpiece - tool interactions are integrated in the friction model. The values of three force components were consequently measured during tool wear tests at different cutting speeds they were used as input data for computing the friction and normal forces acting on the rake and flank faces and, as a result, for determining the relevant friction coefficients. It was observed that both friction coefficients are sensitive to tool wear progression depending on the cutting speed used. For comparison the values of friction coefficient were determined for orthogonal (2D) friction model. The 3D friction model was tested for the machining of spheroidal cast iron (SCI) using uncoated nitride ceramic inserts.Prowadzono analizę tarcia w operacjach toczenia wzdłużnego z użyciem narzędzi z niepowlekanej ceramiki azotowej. W przyjętym modelu tarcia uwzględniono synergię oddziaływania na styku ostrze - wiór i przedmiot - ostrze. Wykonano pomiary wartości trzech sił składowych w czasie próby zużycia ostrza dla różnych wartości prędkości skrawania. Określane wartości użyto jako dane wejściowe do wyznaczenia wartości siły tarcia i siły normalnej, i w kolejności do wyznaczenia wartości określonego współczynnika tarcia. Stwierdzono, że współczynnik tarcia jest wrażliwy na przyrost zużycia narzędzia, zależnie od prędkości skrawania. W celu porównania wyznaczono wartości współczynnika tarcia dla ortogonalnego (2D) modelu tarcia. Weryfikację modelu 3D tarcia prowadzono dla skrawania żeliwa sferoidalnego z zastosowaniem niepowlekanych płytek ostrzowych z ceramiki azotowej