Superior strength and high-temperature performance make γ-TiAl vital for lightweight aero-engines. However, its inherent brittleness poses machining problems. This study employed Elliptical Ultrasonic Vibration Milli...Superior strength and high-temperature performance make γ-TiAl vital for lightweight aero-engines. However, its inherent brittleness poses machining problems. This study employed Elliptical Ultrasonic Vibration Milling (EUVM) to address these problems. Considering the influence of machining parameters on vibration patterns of EUVM, a separation time model was established to analyze the vibration evolutionary process, thereby instructing the cutting mechanism. On this basis, deep discussions regarding chip formation, cutting force, edge breakage, and subsurface layer deformation were conducted for EUVM and Conventional Milling (CM). Chip morphology showed the chip formation was rooted in the periodic brittle fracture. Local dimples proved that the thermal effect of high-speed cutting improved the plasticity of γ-TiAl. EUVM achieved a maximum 18.17% reduction in cutting force compared with CM. The force variation mechanism differed with changes in the cutting speed or the vibration amplitude, and its correlation with thermal softening, strain hardening, and vibratory cutting effects was analyzed. EUVM attained desirable edge breakage by achieving smaller fracture lengths. The fracture mechanisms of different phases were distinct, causing a surge in edge fracture size of γ-TiAl under microstructural differences. In terms of subsurface deformation, EUVM also showed strengthening effects. Noteworthy, the lamellar deformation patterns under the cutting removal state differed from the quasi-static, which was categorized by the orientation angles. Additionally, the electron backscattering diffraction provided details of the influence of microstructural difference on the orientation and the deformation of grains in the subsurface layer. The results demonstrate that EUVM is a promising machining method for γ-TiAl and guide further research and development of EUVM γ-TiAl.展开更多
Tip clearances of multistage rotors and stators greatly affect aero-engines’ aerodynamic efficiency, stability and safety. The inevitable machining and assembly errors, as well as the complicated error propagation me...Tip clearances of multistage rotors and stators greatly affect aero-engines’ aerodynamic efficiency, stability and safety. The inevitable machining and assembly errors, as well as the complicated error propagation mechanism, cause overproof or non-uniform tip clearances. However, it is generally accepted that tip clearances are difficult to predict, even under assembly state. In this paper, a tip clearance prediction model is proposed based on measured error data. Some 3 D error propagation sub-models, regarding rotors, supports and casings, are built and combined. The complex error coupling relationship is uncovered using mathematical methods. Rotor and stator tip clearances are predicted and analyzed in different phase angles. The maximum, minimum and average tip clearances can be calculated. The proposed model is implemented by a computer program,and a case study illustrates its performance and verifies its feasibility. The results can be referred by engineers in assembly quality judgement and decision-making.展开更多
Ti-6Al-4V is widely used in the aviation industry because of its high strength, and good heat resistance. However, severe tool wear on the rake face occurs during the milling of Ti-6Al-4V,which is caused by intense fr...Ti-6Al-4V is widely used in the aviation industry because of its high strength, and good heat resistance. However, severe tool wear on the rake face occurs during the milling of Ti-6Al-4V,which is caused by intense friction between the tool rake face and the chips. To investigate tool wear in the milling of Ti-6Al-4V, ultrasonic vibration is introduced, and a cutting force prediction model that considers tool-chip contact interface friction behavior in Ultrasonic Longitudinal-Torsional Vibration-Assisted Milling(ULTVAM) is proposed in this paper. First, the tool tip motion trajectory and dynamic cutting thickness under ULTVAM were analyzed calculated, and compared with those in Common Milling(CM). Subsequently, the effects of ultrasonic vibration on the shear force under the ultrasonic softening effect, the friction force, and the friction reversal force on the toolchip contact interface were investigated. A dynamic milling force model under ULTVAM was established before and after friction force reversal caused by ultrasonic longitudinal-torsional vibration. Finally, numerous experiments were conducted to validate the proposed model, and the experimental results indicated that the calculated dynamic milling forces agreed well with the measured values, with errors in the X and Y directions of 5.51% and 10.23%, respectively. In addition, the average roughness of the workpiece surface also decreased(1.08, 0.9, 0.6, 0.7 μm under ultrasonic amplitudes of 0, 1, 2, and 3 μm) and the tool wear state improved on the rake face under ULTVAM.展开更多
Ultrasonic vibration-assisted milling has been widely applied in machining the difficultto-cut materials owing to the remarkable improvements in reducing the cutting force.However,analytical models to reveal the mecha...Ultrasonic vibration-assisted milling has been widely applied in machining the difficultto-cut materials owing to the remarkable improvements in reducing the cutting force.However,analytical models to reveal the mechanism and predict the cutting force of ultrasonic vibrationassisted milling metal matrix composites are still needed to be developed.In this paper,an analytical model of cutting force was established for ultrasonic vibration-assisted milling in-situ TiB_(2)/7050 Al metal matrix composites.During modeling,change of motion of the cutting tool,contact of toolchip-workpiece and acceleration of the chip caused by ultrasonic vibration was considered based on equivalent oblique cutting model.Meanwhile,material properties,tool geometry,cutting parameters and vibration parameters were taken into consideration.Furthermore,the developed analytical force model was validated with and without ultrasonic vibration milling experiments on in-situ TiB_(2)/7050 Al metal matrix composites.The predicted cutting forces show to be consistent well with the measured cutting forces.Besides,the relative error of instantaneous maximum forces between the predicted and measured data is from 0.4%to 15.1%.The analytical model is significant for cutting force prediction not only in ultrasonic-vibration assisted milling but also in conventional milling in-situ TiB_(2)/7050 Al metal matrix composites,which was proved with general applicability.展开更多
Excellent surface integrity is an eternal pursuit in high performance manufacturing, with microstructure being a crucial component of the surface integrity dataset and a key factor controlling surface properties such ...Excellent surface integrity is an eternal pursuit in high performance manufacturing, with microstructure being a crucial component of the surface integrity dataset and a key factor controlling surface properties such as fatigue and creep. The multi-physical fields generated by thermomechanical loads during high-speed machining act on the processed surface layer, influencing the evolution of microstructures. To investigate the microstructural evolution mechanisms of ATI718plus during high-speed machining, cutting experiments and techniques such as Electron back scatter diffraction(EBSD), Transmission Kikuchi diffraction(TKD), and Precession electron diffraction(PED) is conducted to quantitatively analyze the microstructures in the chip shear zone and the machined surface. Subsequently, a combined finite element(FE) and cellular automata(CA) model is developed to simulate the microstructure evolution during the cutting process. The discontinuous dynamic recrystallization(DDRX) mechanism is employed to demonstrate the nucleation and growth of grains under the influence of multiple physical fields. The simulation and experimental results show similar dynamic recrystallization(DRX) grain sizes, indicating acceptable accuracy of the CA model in terms of DRX grain size. The comparison between experimental and simulation results confirms the occurrence of both continuous dynamic recrystallization(CDRX) and DDRX during the cutting process. The synergistic competition between CDRX induced grain lamellar refinement and DDRX induced grain growth emerge as the primary mechanism driving microstructural evolution. A layer of ultrafine grains, with a thickness within 20 μm, is formed on the machined surface. Results under different parameters demonstrate that the temperature has a more significant impact on the thickness of the ultrafine grain layer and the diameter of grains within the layer compared to the strain rate.展开更多
Owing to its outstanding mechanical properties,γ-TiAl is desirable materials for crossgeneration aero-engines.Nearly 70 years of exploration have made it into the initial application.However,the intrinsic brittleness...Owing to its outstanding mechanical properties,γ-TiAl is desirable materials for crossgeneration aero-engines.Nearly 70 years of exploration have made it into the initial application.However,the intrinsic brittleness ofγ-TiAl is still a critical obstacle to its large-scale applications.In this context,researchers have made many attempts to study the machinability ofγ-TiAl.At present,existing relevant reviews have mostly discussed the processing methods ofγ-TiAl.Hence,there is still a lack of a perspective on material properties to analyze the cutting mechanism.Herein,this paper provides the systematic review of such perspectives.Above all,the developmental process,phase transformation,and microstructural evolution ofγ-TiAl are discussed,as well as its deformation mechanism at quasi-static.These topics can provide a materials science foundation for the machining ofγ-TiAl.And then,the review focuses on the cutting mechanism and surface integrity ofγ-TiAl.Moreover,special attention is paid to the microscope deformation mechanism and surface defects evolution ofγ-TiAl during cutting.Finally,the review indicates that the highperformance machining technology ofγ-TiAl faces challenges and proposes potential future research directions.Solving the difficulties during machiningγ-TiAl aero-engine components will accelerate the development of new aero-engines.展开更多
Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining qualit...Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.展开更多
For higher efficiency and precision manufacturing,more and more attentions are focused on the surface roughness and residual stress of machined parts to obtain a good fatigue life.At present,the in-situ TiB_2/7050 Al ...For higher efficiency and precision manufacturing,more and more attentions are focused on the surface roughness and residual stress of machined parts to obtain a good fatigue life.At present,the in-situ TiB_2/7050 Al metal matrix composites are widely researched due to its attractive properties such as low density,good wear resistance and improved strength.It is of great significance to investigate the machined surface roughness,residual stress and fatigue life for higher efficiency and precision manufacturing of this new kind material.In this study,the surface roughness including two-dimensional and three-dimensional roughness,residual stress and fatigue life of milling in-situ TiB_2/7050 Al metal matrix composites were analyzed.It was found from comparative investigation that the three-dimensional surface roughness would be more appropriate to represent the machined surface profile of milling particle reinforced metal matrix composites.The cutting temperature played a great role on the residual stress.However,the effect of increasing cutting force could slow down the transformation from compressive stress to tensile stress under 270°C.An exponential relationship between three-dimensional roughness and fatigue life was established and the main fracture mechanism was brittle fracture with observation of obvious shellfish veins,river pattern veins and wave shaped veins in fracture surface.展开更多
Solving the shortest tool length quickly under a known tool trajectory in multi-axis machining of complex channel parts is an urgent problem in industrial production. To solve this problem, a novel and efficient metho...Solving the shortest tool length quickly under a known tool trajectory in multi-axis machining of complex channel parts is an urgent problem in industrial production. To solve this problem, a novel and efficient method is proposed which is featured by extracting only a few necessary curves from the check surface instead of sampling the entire surface. By rotating and compressing the 3 D check surface relative to all tool postures, the boundaries of the area occupied by the 2 D compressed surfaces are the essential elements for determining the shortest tool length. A tracking-based numerical algorithm is introduced to efficiently solve the silhouette curves which are formed in compressing. To define the multi-taper shaped tool holding system(THS) which is commonly used in production, a characterization model for THS profile is established. A model for solving the shortest tool length is finally constructed based on the critical interference relationship between the THS profile and all compressed boundary curves. For acceleration, the boundary splines are segmented according to their knot vectors. Then a new concept called the axis-aligned tool length box(AATB) is introduced,which can provide a conservative range of tool length for a spline segment. By scanning the AATBs of all spline segments, the very few effective spline segments that may ultimately determine the shortest tool length are filtered out. This acceleration method makes the solution for the shortest tool length more focused and efficient. The results of experimental examples are also reported to validate the efficiency and accuracy of the proposed algorithm.展开更多
The deviation in wall thickness caused by core shift during the investment casting process significantly impacts the strength and service life of hollow turbine blades.To address this issue,a core shift limitation met...The deviation in wall thickness caused by core shift during the investment casting process significantly impacts the strength and service life of hollow turbine blades.To address this issue,a core shift limitation method is developed in this study.Firstly,a shift model is established based on computational fluid dynamics and motion simulation to predict the movement of the ceramic core in investment casting process.Subsequently,utilizing this model,an optimization method for fixturing layout inside the refractory ceramic shell is devised for the ceramic core.The casting experiment demonstrates that by utilizing the optimized fixture layout,not only can core shift during the investment casting pouring process be effectively controlled,but also the maximum wall thickness error of the blade can be reduced by 42.02%.In addition,the core shift prediction is also validated,with a prediction error of less than 26.9%.展开更多
Ultrasonic vibration-assisted drilling(UVAD)has recently been successfully applied in the drilling of carbon fiber reinforced polymer/plastic(CFRP)due to its high reliability.Multiple defects have been observed in the...Ultrasonic vibration-assisted drilling(UVAD)has recently been successfully applied in the drilling of carbon fiber reinforced polymer/plastic(CFRP)due to its high reliability.Multiple defects have been observed in the CFRP drilling process which negatively affects the quality of the hole.The carbon fiber/bismaleimide(BMI)composites is an advanced kind of CFRPs with greater strength and heat resistance,having been rapidly applied in lightweight and high temperature resistant structures in the aerospace field.To suppress the defect during the drilling of carbon fiber/BMI composites,it is necessary to comprehensively understand the defect formation and suppression mechanism at different positions.In this study,the defects formation in both conventional drilling(CD)and UVAD were observed and analyzed.The variation trend in the defect factor and thrust force with the spindle speed and feed rate were acquired.The results revealed that the UVAD could significantly enhance the hole’s quality with no delamination and burr.Meanwhile,the defect suppression mechanism and thrust force in UVAD were analyzed and verified,where the method of rod chip removal affected the exit defect formation.In summary,UVAD can be considered a promising and competitive technique for drilling carbon fiber/BMI composites.展开更多
For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two i...For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).展开更多
Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional ph...Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.展开更多
Interfaces play a crucial role in influencing the mechanical properties of Mg alloys.For Mg-Li dual-phase alloy,the type of interfaces is complex,which includes both grain boundary and phase boundary,and the influence...Interfaces play a crucial role in influencing the mechanical properties of Mg alloys.For Mg-Li dual-phase alloy,the type of interfaces is complex,which includes both grain boundary and phase boundary,and the influence of such interfaces on the damage nucleation is yet to be explored.In this paper,in-situ scanning electron microscopy(SEM)based measurements were carried out to investigate the meso-scale damage nucleation mechanisms of the Mg-6Li dual-phase alloy.Results show that 94.8%of cracks are nucleated at the α-Mg grain boundary in the post-uniform elongation stage,while 5.2%are at phase boundary and almost no crack at the β-Li grain boundary.The initiation of α-Mg grain boundary cracks is attributed to strain incompatibility,which induces micro-strain localization,and then causes grain boundary sliding(GBS)and crack nucleation.Deformation compatibility analysis reveals that the geometric compatibility factor(Mk)can be used to predict the nucleation of α-Mg grain boundary crack.When Mk is lower than 0.075,α-Mg grain boundary cracks tend to form.Few cracks are generated at the phase boundary is due to the mild strain partitioning between α-Mg phase and β-Li phase and may also be partly attributed to multiple slip systems in body-centered cubic(BCC)-structured β-Li phase,which can accommodate well with the deformation of adjacent α-Mg phase.展开更多
Machined surface roughness will affect parts?service performance.Thus,predicting it in the machining is important to avoid rejects.Surface roughness will be affected by system position dependent vibration even under c...Machined surface roughness will affect parts?service performance.Thus,predicting it in the machining is important to avoid rejects.Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing.Aiming at surface roughness prediction in the machining process,this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis.To reduce the stochastic error of measuring the machined surface profile height,the surface area is repeatedly measured three times,and Pauta criterion is adopted to eliminate abnormal points.The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model.Seven acceleration features are extracted,and valley,which has the highest/^-square proving the effectiveness of the filtering features,is selected as the input of the prediction model by mutual information coefficients.Finally,by comparing the measured and predicted surface roughness curves,they have the same trends,with the average error of 16.28%and the minimum error of 0.16%.Moreover,the prediction curve matches and agrees well with the actual surface state,which verifies the accuracy and reliability of the model.展开更多
基金co-supported by the Science Center for Gas Turbine Project, China(No. P2022-AB-IV-001-002)the National Natural Science Foundation of China (No. 91960203)+1 种基金the Fundamental Research Funds for the Central Universities (No. D5000230048)the Innovation Capability Support Program of Shaanxi (No. 2022TD-60)
文摘Superior strength and high-temperature performance make γ-TiAl vital for lightweight aero-engines. However, its inherent brittleness poses machining problems. This study employed Elliptical Ultrasonic Vibration Milling (EUVM) to address these problems. Considering the influence of machining parameters on vibration patterns of EUVM, a separation time model was established to analyze the vibration evolutionary process, thereby instructing the cutting mechanism. On this basis, deep discussions regarding chip formation, cutting force, edge breakage, and subsurface layer deformation were conducted for EUVM and Conventional Milling (CM). Chip morphology showed the chip formation was rooted in the periodic brittle fracture. Local dimples proved that the thermal effect of high-speed cutting improved the plasticity of γ-TiAl. EUVM achieved a maximum 18.17% reduction in cutting force compared with CM. The force variation mechanism differed with changes in the cutting speed or the vibration amplitude, and its correlation with thermal softening, strain hardening, and vibratory cutting effects was analyzed. EUVM attained desirable edge breakage by achieving smaller fracture lengths. The fracture mechanisms of different phases were distinct, causing a surge in edge fracture size of γ-TiAl under microstructural differences. In terms of subsurface deformation, EUVM also showed strengthening effects. Noteworthy, the lamellar deformation patterns under the cutting removal state differed from the quasi-static, which was categorized by the orientation angles. Additionally, the electron backscattering diffraction provided details of the influence of microstructural difference on the orientation and the deformation of grains in the subsurface layer. The results demonstrate that EUVM is a promising machining method for γ-TiAl and guide further research and development of EUVM γ-TiAl.
基金co-supported by the Equipment Pre-Research Foundation (No. 61409230204)the National Basic Research Project (No. 2017-VII-0010-0104)+2 种基金the Defense Industrial Technology Development Program (No. XXXX2018213A001)the National Natural Science Foundation of China(No. 51875475)the Key Development Program of Shaanxi Province (Nos. 2018ZDXM-GY-068 and 2016KTZDGY4-02)。
文摘Tip clearances of multistage rotors and stators greatly affect aero-engines’ aerodynamic efficiency, stability and safety. The inevitable machining and assembly errors, as well as the complicated error propagation mechanism, cause overproof or non-uniform tip clearances. However, it is generally accepted that tip clearances are difficult to predict, even under assembly state. In this paper, a tip clearance prediction model is proposed based on measured error data. Some 3 D error propagation sub-models, regarding rotors, supports and casings, are built and combined. The complex error coupling relationship is uncovered using mathematical methods. Rotor and stator tip clearances are predicted and analyzed in different phase angles. The maximum, minimum and average tip clearances can be calculated. The proposed model is implemented by a computer program,and a case study illustrates its performance and verifies its feasibility. The results can be referred by engineers in assembly quality judgement and decision-making.
基金the National Natural Science Foundation of China(No.52475516,52005166,91960203)the Young Core Instructor Project in the Higher Education Institutions of Henan Province(No.2023GGJS051)the National Science Fund for Distinguished Young Scholars of Henan Polytechnic University(No.J2022-5).
文摘Ti-6Al-4V is widely used in the aviation industry because of its high strength, and good heat resistance. However, severe tool wear on the rake face occurs during the milling of Ti-6Al-4V,which is caused by intense friction between the tool rake face and the chips. To investigate tool wear in the milling of Ti-6Al-4V, ultrasonic vibration is introduced, and a cutting force prediction model that considers tool-chip contact interface friction behavior in Ultrasonic Longitudinal-Torsional Vibration-Assisted Milling(ULTVAM) is proposed in this paper. First, the tool tip motion trajectory and dynamic cutting thickness under ULTVAM were analyzed calculated, and compared with those in Common Milling(CM). Subsequently, the effects of ultrasonic vibration on the shear force under the ultrasonic softening effect, the friction force, and the friction reversal force on the toolchip contact interface were investigated. A dynamic milling force model under ULTVAM was established before and after friction force reversal caused by ultrasonic longitudinal-torsional vibration. Finally, numerous experiments were conducted to validate the proposed model, and the experimental results indicated that the calculated dynamic milling forces agreed well with the measured values, with errors in the X and Y directions of 5.51% and 10.23%, respectively. In addition, the average roughness of the workpiece surface also decreased(1.08, 0.9, 0.6, 0.7 μm under ultrasonic amplitudes of 0, 1, 2, and 3 μm) and the tool wear state improved on the rake face under ULTVAM.
基金sponsored by National Natural Science Foundation of China(No.51775443)National Science and Technology Major Project of China(No.2017-Ⅶ-0015-0111)。
文摘Ultrasonic vibration-assisted milling has been widely applied in machining the difficultto-cut materials owing to the remarkable improvements in reducing the cutting force.However,analytical models to reveal the mechanism and predict the cutting force of ultrasonic vibrationassisted milling metal matrix composites are still needed to be developed.In this paper,an analytical model of cutting force was established for ultrasonic vibration-assisted milling in-situ TiB_(2)/7050 Al metal matrix composites.During modeling,change of motion of the cutting tool,contact of toolchip-workpiece and acceleration of the chip caused by ultrasonic vibration was considered based on equivalent oblique cutting model.Meanwhile,material properties,tool geometry,cutting parameters and vibration parameters were taken into consideration.Furthermore,the developed analytical force model was validated with and without ultrasonic vibration milling experiments on in-situ TiB_(2)/7050 Al metal matrix composites.The predicted cutting forces show to be consistent well with the measured cutting forces.Besides,the relative error of instantaneous maximum forces between the predicted and measured data is from 0.4%to 15.1%.The analytical model is significant for cutting force prediction not only in ultrasonic-vibration assisted milling but also in conventional milling in-situ TiB_(2)/7050 Al metal matrix composites,which was proved with general applicability.
基金supported by National Natural Science Foundation of China(Nos.92160301,92360309)Science Center for Gas Turbine Project(Grant No.P2022-AB-Ⅳ-001-002)+1 种基金Shaanxi Provincial Key Research and Development Program(No.2021ZDLGY10-06)Innovation Capability Support Program of Shaanxi(Program No.2022TD-60).
文摘Excellent surface integrity is an eternal pursuit in high performance manufacturing, with microstructure being a crucial component of the surface integrity dataset and a key factor controlling surface properties such as fatigue and creep. The multi-physical fields generated by thermomechanical loads during high-speed machining act on the processed surface layer, influencing the evolution of microstructures. To investigate the microstructural evolution mechanisms of ATI718plus during high-speed machining, cutting experiments and techniques such as Electron back scatter diffraction(EBSD), Transmission Kikuchi diffraction(TKD), and Precession electron diffraction(PED) is conducted to quantitatively analyze the microstructures in the chip shear zone and the machined surface. Subsequently, a combined finite element(FE) and cellular automata(CA) model is developed to simulate the microstructure evolution during the cutting process. The discontinuous dynamic recrystallization(DDRX) mechanism is employed to demonstrate the nucleation and growth of grains under the influence of multiple physical fields. The simulation and experimental results show similar dynamic recrystallization(DRX) grain sizes, indicating acceptable accuracy of the CA model in terms of DRX grain size. The comparison between experimental and simulation results confirms the occurrence of both continuous dynamic recrystallization(CDRX) and DDRX during the cutting process. The synergistic competition between CDRX induced grain lamellar refinement and DDRX induced grain growth emerge as the primary mechanism driving microstructural evolution. A layer of ultrafine grains, with a thickness within 20 μm, is formed on the machined surface. Results under different parameters demonstrate that the temperature has a more significant impact on the thickness of the ultrafine grain layer and the diameter of grains within the layer compared to the strain rate.
基金co-supported by the Science Center for Gas Turbine Project,China(No.P2022-A-IV-001-002)the National Natural Science Foundation of China(Nos.51875473 and 91960203).
文摘Owing to its outstanding mechanical properties,γ-TiAl is desirable materials for crossgeneration aero-engines.Nearly 70 years of exploration have made it into the initial application.However,the intrinsic brittleness ofγ-TiAl is still a critical obstacle to its large-scale applications.In this context,researchers have made many attempts to study the machinability ofγ-TiAl.At present,existing relevant reviews have mostly discussed the processing methods ofγ-TiAl.Hence,there is still a lack of a perspective on material properties to analyze the cutting mechanism.Herein,this paper provides the systematic review of such perspectives.Above all,the developmental process,phase transformation,and microstructural evolution ofγ-TiAl are discussed,as well as its deformation mechanism at quasi-static.These topics can provide a materials science foundation for the machining ofγ-TiAl.And then,the review focuses on the cutting mechanism and surface integrity ofγ-TiAl.Moreover,special attention is paid to the microscope deformation mechanism and surface defects evolution ofγ-TiAl during cutting.Finally,the review indicates that the highperformance machining technology ofγ-TiAl faces challenges and proposes potential future research directions.Solving the difficulties during machiningγ-TiAl aero-engine components will accelerate the development of new aero-engines.
基金supported by the National Natural Science Foundation of China(Nos.52005413,52022082)Natural Science Basic Research Plan in Shaanxi Province of China(No.2021JM-054)the Fundamental Research Funds for the Central Universities(No.D5000220135)。
文摘Geometric error,mainly due to imperfect geometry and dimensions of machine components,is one of the major error sources of machine tools.Considering that geometric error has significant effects on the machining quality of manufactured parts,it has been a popular topic for academic and industrial research for many years.A great deal of research work has been carried out since the 1970s for solving the problem and improving the machining accuracy.Researchers have studied how to measure,detect,model,identify,reduce,and compensate the geometric errors.This paper presents a thorough review of the latest research activities and gives an overview of the state of the art in understanding changes in machine tool performance due to geometric errors.Recent advances in measuring the geometrical errors of machine tools are summarized,and different kinds of error identification methods of translational axes and rotation axes are illustrated respectively.Besides,volumetric geometric error modeling,tracing,and compensation techniques for five-axis machine tools are emphatically introduced.Finally,research challenges in order to improve the volumetric accuracy of machine tools are also highlighted.
基金National Natural Science Foundation of China(No.51775443)National Science and Technology Major Project of China(No.2017-VII-00150111)。
文摘For higher efficiency and precision manufacturing,more and more attentions are focused on the surface roughness and residual stress of machined parts to obtain a good fatigue life.At present,the in-situ TiB_2/7050 Al metal matrix composites are widely researched due to its attractive properties such as low density,good wear resistance and improved strength.It is of great significance to investigate the machined surface roughness,residual stress and fatigue life for higher efficiency and precision manufacturing of this new kind material.In this study,the surface roughness including two-dimensional and three-dimensional roughness,residual stress and fatigue life of milling in-situ TiB_2/7050 Al metal matrix composites were analyzed.It was found from comparative investigation that the three-dimensional surface roughness would be more appropriate to represent the machined surface profile of milling particle reinforced metal matrix composites.The cutting temperature played a great role on the residual stress.However,the effect of increasing cutting force could slow down the transformation from compressive stress to tensile stress under 270°C.An exponential relationship between three-dimensional roughness and fatigue life was established and the main fracture mechanism was brittle fracture with observation of obvious shellfish veins,river pattern veins and wave shaped veins in fracture surface.
基金support of National Science and Technology Major Project of China (No. JPPTKF2016)。
文摘Solving the shortest tool length quickly under a known tool trajectory in multi-axis machining of complex channel parts is an urgent problem in industrial production. To solve this problem, a novel and efficient method is proposed which is featured by extracting only a few necessary curves from the check surface instead of sampling the entire surface. By rotating and compressing the 3 D check surface relative to all tool postures, the boundaries of the area occupied by the 2 D compressed surfaces are the essential elements for determining the shortest tool length. A tracking-based numerical algorithm is introduced to efficiently solve the silhouette curves which are formed in compressing. To define the multi-taper shaped tool holding system(THS) which is commonly used in production, a characterization model for THS profile is established. A model for solving the shortest tool length is finally constructed based on the critical interference relationship between the THS profile and all compressed boundary curves. For acceleration, the boundary splines are segmented according to their knot vectors. Then a new concept called the axis-aligned tool length box(AATB) is introduced,which can provide a conservative range of tool length for a spline segment. By scanning the AATBs of all spline segments, the very few effective spline segments that may ultimately determine the shortest tool length are filtered out. This acceleration method makes the solution for the shortest tool length more focused and efficient. The results of experimental examples are also reported to validate the efficiency and accuracy of the proposed algorithm.
基金the National Natural Science Foundation of China(Grant No.52005311)the Scientific and the National Science and Technology Major Project(Grant No.J2019-VII-0013-0153)Research Project Supported by Shanxi Scholarship Council of China(Grant No.2023-003).
文摘The deviation in wall thickness caused by core shift during the investment casting process significantly impacts the strength and service life of hollow turbine blades.To address this issue,a core shift limitation method is developed in this study.Firstly,a shift model is established based on computational fluid dynamics and motion simulation to predict the movement of the ceramic core in investment casting process.Subsequently,utilizing this model,an optimization method for fixturing layout inside the refractory ceramic shell is devised for the ceramic core.The casting experiment demonstrates that by utilizing the optimized fixture layout,not only can core shift during the investment casting pouring process be effectively controlled,but also the maximum wall thickness error of the blade can be reduced by 42.02%.In addition,the core shift prediction is also validated,with a prediction error of less than 26.9%.
基金co-supported by the Sichuan Science and Technology Program(Grant No.2020YFG0109)the NSAF of China(Grant No.U1830122).
文摘Ultrasonic vibration-assisted drilling(UVAD)has recently been successfully applied in the drilling of carbon fiber reinforced polymer/plastic(CFRP)due to its high reliability.Multiple defects have been observed in the CFRP drilling process which negatively affects the quality of the hole.The carbon fiber/bismaleimide(BMI)composites is an advanced kind of CFRPs with greater strength and heat resistance,having been rapidly applied in lightweight and high temperature resistant structures in the aerospace field.To suppress the defect during the drilling of carbon fiber/BMI composites,it is necessary to comprehensively understand the defect formation and suppression mechanism at different positions.In this study,the defects formation in both conventional drilling(CD)and UVAD were observed and analyzed.The variation trend in the defect factor and thrust force with the spindle speed and feed rate were acquired.The results revealed that the UVAD could significantly enhance the hole’s quality with no delamination and burr.Meanwhile,the defect suppression mechanism and thrust force in UVAD were analyzed and verified,where the method of rod chip removal affected the exit defect formation.In summary,UVAD can be considered a promising and competitive technique for drilling carbon fiber/BMI composites.
基金supported in part by Foshan HKUST Projects(Project ID:FSUST20-SRI09E–FSPM02202007-1)the Project of Hetao Shenzhen-Hong Kong Science and Technology Innovation Cooperation Zone(Project ID:HZQB-KCZYB-2020083)the National Science and Technology Major Project(Grant No.J2019-VII-0001-0141)。
文摘For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main purpose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solution,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel twophase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the proposed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36%of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).
基金co-supported by the National Basic Research Project(Nos.J2022-VII-0001-0043 and 2017-VII-0010-0104)the Fundamental Research Funds for the Central Universities,and the National Natural Science Foundation of China(No.72231008)。
文摘Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.
基金National Natural Science Foundation of China(Nos.52005412,52305506 and U2241231)Fundamental Research Funds for the Central Universities(No.D5000230081).
文摘Interfaces play a crucial role in influencing the mechanical properties of Mg alloys.For Mg-Li dual-phase alloy,the type of interfaces is complex,which includes both grain boundary and phase boundary,and the influence of such interfaces on the damage nucleation is yet to be explored.In this paper,in-situ scanning electron microscopy(SEM)based measurements were carried out to investigate the meso-scale damage nucleation mechanisms of the Mg-6Li dual-phase alloy.Results show that 94.8%of cracks are nucleated at the α-Mg grain boundary in the post-uniform elongation stage,while 5.2%are at phase boundary and almost no crack at the β-Li grain boundary.The initiation of α-Mg grain boundary cracks is attributed to strain incompatibility,which induces micro-strain localization,and then causes grain boundary sliding(GBS)and crack nucleation.Deformation compatibility analysis reveals that the geometric compatibility factor(Mk)can be used to predict the nucleation of α-Mg grain boundary crack.When Mk is lower than 0.075,α-Mg grain boundary cracks tend to form.Few cracks are generated at the phase boundary is due to the mild strain partitioning between α-Mg phase and β-Li phase and may also be partly attributed to multiple slip systems in body-centered cubic(BCC)-structured β-Li phase,which can accommodate well with the deformation of adjacent α-Mg phase.
基金This work was supported by the National Natural Science Foundation of China(Grant Nos.52022082 and 52005413)the 111 Project(Grant No.B13044).
文摘Machined surface roughness will affect parts?service performance.Thus,predicting it in the machining is important to avoid rejects.Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing.Aiming at surface roughness prediction in the machining process,this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis.To reduce the stochastic error of measuring the machined surface profile height,the surface area is repeatedly measured three times,and Pauta criterion is adopted to eliminate abnormal points.The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model.Seven acceleration features are extracted,and valley,which has the highest/^-square proving the effectiveness of the filtering features,is selected as the input of the prediction model by mutual information coefficients.Finally,by comparing the measured and predicted surface roughness curves,they have the same trends,with the average error of 16.28%and the minimum error of 0.16%.Moreover,the prediction curve matches and agrees well with the actual surface state,which verifies the accuracy and reliability of the model.
