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EN
The subject of this research is convergence technology for the surface finishing of vehicle parts. A literature review has been conducted to carry out a comparative analysis of existing methods for the surface finishing of parts used in the manufacturing of aircraft, hydraulic and pneumatic devices, and other vehicles. Prospects are shown for further research on methods with the aim of creating a complex technology (i.e., convergence) that combines information technologies; nanotechnologies; and thermochemical, electrochemical, and mechanical processing methods. A method is proposed for selecting and combining surface finishing methods according to a five-point expert assessment, which allows the batch processing of vehicle parts. Based on this method, the concept of convergence technology for the surface finishing of vehicle parts is proposed, which includes the impulse thermal energy method, honing, superfinishing, and electrochemical processing. An expanded process is presented for manufacturing parts with high-precision, low-roughness surfaces and a specified microrelief by using electrochemical superfinishing and electrochemical honing. A scheme of the concentration (focusing) of the current flow during electrochemical superfinishing due to the movement of the electrode relative to the part surface is proposed, which enables the effect of surface polishing and the removal of oxidation products. Convergence technology for the surface finishing of vehicle parts will provide parts’ geometric dimensions with micro- and nano-precision and allow the precision machining of small-diameter holes and complex profiles, increased machining accuracy (up to 0.001 microns), the possibility of batch processing, and the possibility of process automation.
EN
The article describes the influence of brake pads surface machining and finishing on their friction characteristics. It shows the methods of machining and finishing of the brake pads surface and their influence on noise emission and performance. It shows the brake dynamometer test results obtained on three brake pads which have three different types of surface modification and their detailed analysis and comparison.
EN
The article describes and compares the course of the resistance test of a treated surface against the impact of gravel with the model of the test process. The two series of composite samples with surface treatment underwent a so-called gravel test, followed by the evaluation of the test results. Simultaneously with the tests, the material models of the tested composites were created. The input values obtained were used to create a FEM model. The model describes the response of the surface treatment to the impact of the object i.e. gravel of the given size and weight/number. The modelling results were compared with the results of real tests.
PL
W artykule scharakteryzowano procesy gratowania krawędzi i polerowania powierzchni z wykorzystaniem narzędzi z materiałów ceramicznych bazujących na tlenku glinu. Opisano konstrukcje podstawowych typów narzędzi oraz praktyczne przykłady zastosowania w przemyśle. Oceniono wpływ parametrów obróbki na chropowatość powierzchni obrobionej.
EN
The paper describes edges deburring processes and polishing of the surface using ceramic tools based on aluminum oxide. The construction of basic types of tools and their practical industrial applications were described. The effect of machining parameters on surface roughness was evaluated.
EN
The article presents an example of finishing treatment for aluminum alloys with the use of vibration machining, with loose abrasive media in a closed tumbler. For the analysis of selected properties of the surface layer prepared flat samples of aluminum alloy PA6/2017 in the state after recrystallization. The samples in the first stage were subjected to a treatment of deburring using ceramic media. In a second step polishing process performed with a strengthening metal media. In addition, for comparative purposes was considered. only the case of metal polishing. The prepared samples were subjected to hardness tests and a tangential tensile test. As a result of finishing with vibratory machining, it was possible to remove burrs, flash, rounding sharp edges, smoothing and lightening the surface of objects made. The basic parameters of the surface geometry were obtained using the Talysurf CCI Lite - Taylor Hobson optical profiler. As a result of the tests it can be stated that the greatest reduction of surface roughness and mass loss occurs in the first minutes of the process. Mechanical tests have shown that the most advantageous high values of tensile strength and hardness are obtained with two-stage vibration treatment, - combination of deburring and polishing. Moreover the use of metal media resulted in the strengthening of the surface by pressure deburring with metal media.
PL
W artykule przedstawiono wyniki badań dotyczące wpływu warunków obróbki rotacyjno-kaskadowej na kształtowanie morfologii i struktury geometrycznej powierzchni wałków stalowych. Zakres prezentowanych badań obejmował próby obróbki wałeczków stalowych w wygładzarce rotacyjno-kaskadowej z zastosowaniem różnego typu ceramicznych kształtek ściernych firmy Marbad. Określono również zużywalności i skrawności kształtek ceramicznych podczas obróbki stalowych wałeczków w wygładzarce rotacyjno-kaskadowej firmy Erba.
EN
In the article the results concerning influence of processing conditions of circular vibratory finishing on shaping of steel surface surface texture have been presented. The range of presented investigation results included tests of machining of steel workpieces using circular vibratory surface finishing machine and different ceramic shaped stones manufactured in Marbad factory. Also wear and machinability of ceramic shaped stones after machining of steel workpieces in Eraba circular vibratory surface finishing machine has been estimated.
PL
W artykule przedstawiono wyniki badań dotyczące wpływu warunków obróbki rotacyjno-kaskadowej na kształtowanie morfologii i struktury geometrycznej powierzchni uchwytów znalowych. Zakres prezentowanych badań obejmował próby obróbki części znalowych w wygładzarce rotacyjno-kaskadowej z zastosowaniem różnego typu poliestrowych kształtek ściernych firmy Marbad. Określono również zużywalność i skrawność kształtek poliestrowych podczas obróbki przedmiotów ze znalu w wygładzarce rotacyjno-kaskadowej firmy Erba.
EN
In the article the results concerning influence of processing conditions of circular vibratory finishing on shaping of zamak morphology and surface texture have been presented. The range of presented investigation results included tests of machining of zamak workpieces using circular vibratory surface finishing machine and different polyester shaped stones manufactured in Marbad factory. Also wear and machinability of polyester shaped stones after machining of zamak workpieces in Eraba circular vibratory surface finishing machine has been estimated.
EN
This material was gathered to observe the effect of surface finishing on rotors made by means of rapid prototyping techniques. Two rapid prototyping methods were used - Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM). Both were finished with the same procedure - a cyanoacrylic coating was applied and further manually finished with abrasive methods. Further microscopic investigation and roughness tests were performed to observe the quality of surface finishing. Rotor samples were finally tested to quantify aerodynamic performance (experimentally, CFD and PIV techniques were involved).
PL
Prezentowane wyniki badań służą zobrazowaniu wpływu obróbki wykańczającej powierzchnie wentylatorów wytworzonych metodami szybkiego prototypowania. Zastosowano dwa rodzaje metod szybkiego prototypowania - SLS (spiekanie wiązką lasera) i jedną z najbardziej rozpowszechnionych metod przetopu pręta tworzywowego (FDM). W obu przypadkach zastosowano analogiczną metodę wykończania surowych elementów przez nałożenie i ręczną obróbkę ścierną powłoki uzyskanej na bazie cyjanoakrylu. Przeprowadzono badania mikroskopowe oraz analizy chropowatości powierzchni w celu określenia właściwości uzyskanej warstwy wierzchniej. Próbki wirników zostały przebadane pod względem osiąganych wyników aerodynamicznych z zastosowaniem pomiarów wagowych i PIV w obszarze eksperymentalnym oraz z zastosowaniem modelowania metodami numerycznej mechaniki płynów.
PL
W artykule przedstawiono wyniki badań zastosowania obróbki wibrościernej do usuwania zadziorów i wygładzania powierzchni tulei wykonanych ze stopu aluminium obrabianych skrawaniem. Badania przeprowadzono na urządzeniu firmy Rollwasch SMD-R 25 o objętości pojemnika 25 dm3. Określono wpływ częstotliwości wymuszeń pojemnika wygładzarki oraz agresywności kształtek ściernych. W badaniach użyto kształtek ściernych o spoiwie poliestrowym o różnych stopniach intensywności ściernych. W celu oceny efektów obróbki dokonano pomiarów struktury geometrycznej powierzchni. Określono wpływ czynników procesu na końcowy efekt wygładzania powierzchni tulei ze stopu EN AW-2017A (AlCuMg1, PA6).
EN
The article presents an analysis of the possibility of applying vibro abrasive machining for smoothing the surface of aluminum alloy. The impact of the frequency and aggressive-ness of abrasive shapes were compared. Tests were performed on a machine Rollwasch SMD-R 25 with a tumblers capacity of 25 dm3 Were used media abrasive related polyester with different intensities abrasives. For smoothed samples was performed measurements the geometrical surface structure. Defined the effect factors on the final result of the process of smoothing the surface of an aluminum alloy EN AW-2017A (AlCuMg1, PA6).
EN
Nickel matrix coatings were sprayed by the Casto-Dyn 8000 torch on a steel substrate, and then subjected to straight turning. Determining of the optimum geometry of indexing is now synonymous with the selection of the optimum shape and dimensions of the insert and of an appropriate holder. According to cutting board, it was selected square, triangular, trigon inserts, made of carbide and of cubic boron nitride (borazon). Machining of nickel-based coatings was carried out for the cutting speed vc = 214 m/min in the case of treatment with borazon inserts, vc = 107 m/min in case of plates treated with tungsten carbide cutting, using the feed f =0.06 mm/rev and the depth of cut ap = 0.3 mm. Metal cutting the surface of steel samples coated with a composite coating containing 15% Al2O3 based on nickel, conducted for the cutting speed vc = 157 m/min when machining with borazon inserts and for vc = 83 m/min inserts with tungsten carbide for feed f = 0.06 mm/rev and depth of cut ap = 0.3 mm. Highly precise finishing of flame spraying composite and alloy coatings was carried out using turning by tool with borazon inserts. Flank (VB) and attack (KB) of turning tool wear while maintaining a constant length of spiral cutting (LSC) were determined. The effect of the shape and grade of inserts upon the geometric structure of the composite coatings and is considered in the paper. The article can determine the shape and grade of inserts is necessary to obtain sufficient quality of the shaft of centrifugal pumps with a composite coating.
EN
The influence of the shape and grade of inserts upon the geometric structure of the composite coatings Ni-5%Al- 15%Al2O3 and alloy coatings of Ni-5% Al is considered in the paper. Nickel matrix coatings were sprayed by the Casto-Dyn 8000 torch on a steel substrate, and then subjected to straight turning. Determining of the optimum geometry of indexing is now synonymous with the selection of the optimum shape and dimensions of the insert and of an appropriate holder. According to cutting board it was selected square, triangular, trigon inserts, made of carbide and of cubic boron nitride (borazon). Machining of nickel-based coatings was carried out for the cutting speed vc = 214 m/min in the case of treatment with borazon inserts, vc = 107m/min in case of plates treated with tungsten carbide cutting, using the feed fn=0.06mm/rev and the depth of cut ap = 0.3 mm. Metal cutting the surface of steel samples coated with a composite coating containing 15% Al2O3 based on nickel, conducted for the cutting speed vc = 157 m/min when machining with borazon inserts and for vc = 83 m/min inserts with tungsten carbide for feed fn = 0.06 mm/rev and depth of cut ap = 0.3 mm. Highly precise finishing of flame spraying composite and alloy coatings was carried out using turning by tool with borazon inserts. Flank (VB) and attack (KB) wear coefficient of inserts while maintaining a constant spiral cutting length (SCL) were determined. Important elements parts (such as engines, pumps, centrifugal separators) are regenerated during long-term utilization. This paper proposes the use of regenerated technology subsonic flame thermal spraying and surface finishing by turning composite and alloy coatings of ship machinery parts.
EN
The paper presents a shape and grade of inserts depending on the surface roughness of the intermetallic coatings NiAl and Ni3Al. Intermetallic coatings on nickel based were sprayed with a torch Casto-Dyn 8000 on the steel samples. Thermal spraying intermetallic coatings have been high surface roughness, and therefore they must to be finishing. Experimental research was conducted for unalloyed steel samples with thermal spraying NiAl and Ni3Al intermetallic coatings. Before applying coatings, the samples surface was properly prepared by stream abrasive working, degreasing and finally by cleaning of oxidation products. To testing cutting inserts shape selects square and trigon made tungsten carbide and cubic boron nitride (borazon). Machining intermetallic nickel based coatings were carried out for the cutting speed vc = 214 m/min in the case of after-machining with inserts of borazon, vc = 107 m/min cutting inserts for tungsten carbide, used feed fn = 0.06 mm/rev and depth of cut ap = 0.3 mm. Intermetallic coatings are characterized by high resistance to tribology wear. These materials are used in such fields of technology, such as: electronics, energy, defense, automotive, aviation, shipbuilding, and more industry. The NiAl and Ni3Al intermetallic have found widespread applications as high – temperature structural material due to their high melting point, low density, good thermal conductivity and excellent oxidation resistance. The paper proposes the finishing flame sprayed intermetallic coatings.
PL
W technologii bezołowiowego lutowania obserwuje się nasilenie zjawiska powstawania pustych przestrzeni w połączeniach lutowanych. Liczba, wielkość i umiejscowienie pustych przestrzeni może w istotny sposób wpływać na jakość połączeń lutowanych, zwłaszcza połączeń podzespołów BGA i CSP. Powstawanie pustych przestrzeni w połączeniu lutowanym jest zwykle przypisywane pułapkowaniu części lotnych z pasty lutowniczej lub z innych materiałów, takich jak płytka drukowana(powłoka lutowna, maska przeciwlutowa) lub metalizacji wyprowadzeń podzespołów. W przypadku bezołowiowych past mogą to być pary rozpuszcza­ników, pary wodnej lub gazy powstające z rozkładu produktów reakcji chemicznych aktywatora topnika podczas procesu lutowania. Ilość i rozmiar pustych przestrzeni w dużej mierze zależy od właściwości reologicznych pasty, proszku lutowniczego i rodzaju topnika w paście, ale też od rodzaju lutownej powłoki zabezpieczającej na płytce drukowanej, jaki i od charakterystyki temperaturowo-czasowej procesu lutowania. Artykuł prezentuje wyniki badań powstawania pustych przestrzeni w odniesieniu do warunków procesu lutowania i rodzaju lutownej powłoki zabezpieczającej płytki. Jakość połączeń lutowanych określano na podstawie kontroli rentgenowskiej, oceny zgładów metalograficznych oraz pomiarów siły ścinania podzespołów.
EN
Implementation of lead-free reflow soldering aggravates some problems with quality and reliability of solder joints. One of the issues is formation of voids that are usually generated by trapped gas within solder joints when solder is at molten state. The outgassing substance is generally produced by the evaporation of the solvent in the solder paste and the rheological additives in the solder paste that may evaporate in the heating process during reflow. The outgassing substance may also be generated by the metallization of the substrate, component or the solder powder surface during the fluxing reaction in the reflow process. The effect of voids on the reliability of solder joint may depend not only on the size, but also on frequency and location. This paper presents results from a study of formation of voids with regards to reflow process and PCB surface finishes. Detection of voids was done by cross-sectional analysis. Shear strength measurements of chip capacitor were also carried out.
15
EN
The main aim of the study is assessment and comparison of the measured surface profiles (2D-arragement) and surface microstereometries (3D-arrangement) produced during hard part turning operations keeping different machining conditions. As a result the paper provides a special contribution to surface roughness generation when turning a 40H low chromium alloy steel (equivalent To AlSl 5140 or DIN 41Cr4) heat treated to the hardness of about 60 HRC, with mixed ceramic cutting tools. Comparable surface roughness values were produced in finish turning with Ra values of about 0,25 micrometer. Some results obtained are compared with those related to finish grinding available in literature.
PL
Głównym zadaniem przedstawionych badań jest ocena i porównanie mierzonych profili powierzchni (odwzorowanie 2D) i mikrostereometrii powierzchni (odwzorowanie 3D) wytworzonej podczas operacji toczenia na twardo w różnych warunkach obróbki. Wyniki stanowią specjalny wkład do generowania chropowatości powierzchni w toczeniu narzędziami z ceramiki mieszanej niskostopowej stali 40H (równoważnej gatunkom AlSI 5140 i DIN 41Cr4) obrobionej cieplnie do twardości około 60 HRC. W operacjach wykańczających wytwarzano porównywalne wartości i chropowatości powierzchni o Ra około 0,25 mikrometra. Niektóre uzyskane wyniki porównano do odpowiednich rezultatów szlifowania wykańczającego dostępnych w literaturze.
16
Content available remote Investigation into the surface finish in milling using a ball nose end mill.
EN
It has been established that machining parameters such as feed per tooth, rational speed, path interval and angle of cutter setting, infuence surface roughness in ball-end milling. A scanning microscope was used for registering and analysing the morphology of milled surface. SEM photographs of surface with longitudinal and lateral profiles are included and discussed. The influence of machining factors on the surface geometrical microstructure is also evaluated. It has been revealed that a ball-end mill should be applied to machining of surfaces non-perpendicular to its axis.
PL
Przedstawiono wpływ parametrów obróbki, takich jak posuw na ostrze, prędkość obrotową, odległość wierszowania i kąt ustawienia frezu, na chropowatość powierzchni obrobionej frezem kulistym. Pokazano zdjęcia morfologii powierzchni frezowanych wykonane na mikroskopie skaningowym oraz dokonano ich analizy. Umieszczono również zdjęcia skaningowe powierzchni wraz z ich profilami wzdłużnymi i poprzecznymi oraz omówiono je. Omówiono wpływ czynników obróbki na mikrostrukturę geometryczną powierzchni. Przeprowadzone badania wykazały, że frez kulisty należy stosować do obróbki powierzchni nieprostopadłych do jego osi.
EN
Electrochemical machining (ECM) process removes material by electrochemical dissolution using current field in electrolyte solution and produces an image of tool. Designing of accurate ECM tools is expensive and a time consuming as it involved a trial and error approach. To eliminate the problems of tools design and to improve accuracy and quality of the machined surface, a new approach of NC-ECM is proposed. This paper presents a modeling and analysis of computer numerical controlled (CNC) ECM process with a ball-end electrode. The effect of input parameters and machining conditions on effectiveness of smoothing and resulting final surface parameters during NC-ECM has been investigated using computer simulation and experimental verification. An appropriate range of input parameters for the optimal effectiveness of smoothing has been identifies. This analysis reveals that NC-ECM is higly effective for surface smoothing after milling operations. The simulation also shows that the use of passivating electrolytes is beneficial in achieving smooth surface and good dimensional accuracy. The simulation results have been experimentally verified using a recently designed and fabricated NC-ECM system.
PL
W pracy przedstawiono analizę procesu wygładzania elektrochemicznego z zastosowaniem sferycznej elektrody (ECM-CNC) ze sterowanym numerycznie ruchem sferycznej elektrody roboczej. Na podstawie zweryfikowanej doświadczalnie symulacji komputerowej uzyskano charakterystyki opisujące wpływ parametrów obróbki oraz elektrolitów na parametry chropowatości obrobionej powierzchni. Wykazano dużą efektywność tego sposobu wygładzania powierzchni o złożonym kształcie, otrzymywanej z frezowania na obrabiarkach numerycznych.
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