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Experimental study on fabricating micro-holes in DD5 single-crystal nickel-based superalloy using electrical discharge drilling

Gong Siqian, Sun Yao, Jin Liya, Su Zhipeng

Archives of Civil and Mechanical Engineering

2020

Vol. 20, no. 3

337--352

The single-crystal superalloy materials have been rapidly developed and widely used in advanced thermal structural components due to their excellent comprehensive physical and chemical properties under high-temperature service conditions. However, conventional micro-hole making results in defects such as edge breakage and burr. In this study, the electrical discharge drilling (EDD) combined with helical microelectrode is first adopted to fabricate DD5 single-crystal nickel-based superalloy. The effects of tool geometry and machining parameters on subsurface damage layer, micro-hole taper, surface morphology, surface roughness and machining time were investigated in detail. Experimental results indicated that helical microelectrode can obtained smoother surface without debris deposition and thinner subsurface damage layer depth lack of micro-cracks compared with cylindrical microelectrodes. Additionally, the computational fluid dynamics model was developed to analyze working fluid movement and reveal effective debris removal mechanism of helical microelectrode. The vortices will be generated in lateral gap fluid between micro-hole and helical microelectrode and have a certain delay time. The surface roughness and dimensional precision of micro-holes fabricated by helical microelectrodes are greatly improved and machining efficiency is also improved by 30.94% compared to cylindrical microelectrodes. This work could provide theoretical and process guidance to assist in realizing high surface quality and low subsurface damage of micro-holes obtained with EDD process.

Robust and automatic measurement of grinding-induced subsurface damage in optical glass K9 based on digital image processing

Zhao Y. J., Yan Y. H., Song K. C., Li H. N.

Archives of Civil and Mechanical Engineering

2018

Vol. 18, no. 1

320--330

Optical glass K9 is a critical kind of optical materials, however experiments have indicated that the mechanical grinding of K9 easily led to subsurface damage (SSD). Although substantial SSD measurement methods have been suggested, the problems including the prior knowledge of SSD and slow measurement speed still impede the reported method applications. To this end, this paper has presented an image-process-based method that can identify and measure the grinding-induced SSD in K9 specimens. By performing grinding trials, the method has been found to be able to accurately (with biggest relative error of 3.13% in comparison with the manually measured results) and quickly (with the measurement speed of 1.68 s per image) measure SSD depths. Without any parameter presetting, the method enables automatic SSD measurements, allowing the users without SSD knowledge to be able to use the method. Moreover, the method has shown the good robustness to the input image size, illumination, tilted specimen placement, and material flaws. The method is therefore anticipated to be meaningful for the industrial manufacturing, design and application of optical glass.

Effect of tool cutter immersion on Al-Si bi-metallic materials in High-Speed-Milling

Sokołowski J. H., Szablewski D., Kasprzak W., Ng E. G., Dumitrescu M.

Journal of Achievements in Materials and Manufacturing Engineering

2006

Vol. 17, nr 1-2

15--20

Purpose: Aluminum-Silicon (Al-Si) alloys are commonly used in the automotive industry. At high Si levels they offer good wear resistance. Abrasive wear however, has been identified as the main insert cutter damage mechanism during High-Speed-Milling (HSM). This study investigates the effect of the tool cutter immersion on Al-Si bi-metallic materials in HSM operation. Design/methodology/approach: This study considers the effects of the tool cutter immersion on the resultant cutting forces, associated machined surface roughness, and machined subsurface microstructural damage caused by the tool cutter during the Minimum Quantity Lubricant – High Speed Milling (MQL-HSM) operation of AlSi bi-metallic materials with varying amounts and morphologies of the silicon phase. Findings: Experimental results indicate that a combination of gray cast iron with the W319 microstructure yields the greatest resistance to the tool cutter rake face during the face milling operation for all investigated tool cutter radial immersions. Machined surface roughness measurements reveal that surface roughness is a function of both the silicon content and morphology, as well as the percentage of tool cutter immersion. Matrix hardness measurements indicate that machining at all immersions has the same effect on compressing the matrix structure. Research limitations/implications: This study considers the effects of the radial tooling immersion and material selection while the speed, feed, and axial depth-of-cut are kept constant. Future work should address variability in the machining parameters in an attempt to maximize tool life, while optimizing the machined surface quality. Practical implications: Material selection affects the machining conditions in HSM of Al-Si bi-metallic materials. As a result careful consideration should be given when tailoring the machining conditions to the cast microstructures. Originality/value: North American automakers rely heavily on Al-Si precision sand cast components. As a result bi-metallic machining has to be often addressed during the face milling of engine blocks and cylinder heads. The research conducted here broadens the understanding of the impact of radial immersion on the machining behavior of Al-Si bi-metallic materials.