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EN
The processes of machining have vital influence on the operating properties of machine parts because they ensure the formation of the required geometrical structure of the working surfaces and the condition of the top layer. In this paper the influence of emulsion mist parameters on Ra, Rz and RSm surface roughness parameters is described when finishing the turning of C45 carbon steel. It was found that cutting parameters have considerably greater influence on roughness parameters in comparison with emulsion mist conditions. When increasing cutting speed from 100 to 300 m/min Ra and Rz values decrease nearly 2 times, but RSm value does not depend on speed. When increasing feed rate from 0.1 to 0.2 mm/rev Ra, Rz and RSm values increase more than twice. Changes of emulsion mass flow and compressed air flow affect roughness parameters reach 9–15% of maximum. It was shown that Parameter Space Investigation method can be used efficiently for quick analysis of tested parameters and optimization of their values.
2
Content available Influences on plasma cutting quality on CNC machine
100%
EN
This article discusses plasma cutting technology and its influences on the quality of the resulting cut. Plasma or a plasma arch consists of positive and negatively charged particles, excited and neutral atoms and molecules. As it contains free particles, it is electrically conductive and thus subject to the effects of the electrical and magnetic field. The basis of CNC machine design is described in the article, which has at least 3 axes (x, y, z), but there are also more technologically demanding applications, such as pipe cutting, profile and cutting using chamfer to prepare surfaces for welding, where these multi-axis devices are frequently used. The principle of plasma cutting and the plasma cutting phase is described in this article. The materials that can be divided by a plasma arc are described in detail, including graphs displaying the dependence of sheet thickness on the cutting speed. The article describes and lists the gases that are used in plasma-arc cutting, such as oxygen, argon, hydrogen and nitrogen. Important components of plasma cutting technology are the parameters that can be adjusted and set before the cutting so that the cut is of good quality. The most comprehensive chapter deals with the influences that affect plasma cutting quality. Cutting quality can be influenced by a number of factors. Everything starts with the proper choice of a CNC machine and a plasma source. The quality also depends on the expertise and experience of the machine operator and the setting of the plasma cutting parameters. This issue of influences on the plasma cutting quality is based on long-term experience in the field of the thermal cutting process.
EN
One of the greatest problems of modern production techniques is the achievement of an appropriate quality at minimal costs and accompanied by the production efficiency increase. Therefore, while designing the production process. The technology used should have a considerable influence on the durability and reliability of machine parts to be produced. During finish treatment, the final dimensions as well as functional properties are imparted to a given element by application of proper treatment type. The engineer has a range of production techniques to choose for the proper surface layer formation. It is crucial to find a suitable solution which will meet the requirements as well as the work conditions of a given machine part. The article presents the results of influence of change of cutting parameters on surface roughness parameter during turning process of stainless steel. A shaft made of 304L stainless steel was used for the research. The chemical composition of steel was measured by Solaris-ccd plus optical spectrometer. The cutting process was carried out on a universal CDS 6250 BX-1000 centre lathes. Measurement of surface roughness was carried out by T8000 profilometer. The turning process was conducted by a cutting tool with Wiper insert. During the turning, the following machining parameters were used: cutting speed Vc [m/min], feed f [mm/rev], cutting depth ap [mm] and additionally changed nose radius r [mm], and tool cutting edge angle ϰr [º]. The results of measurements of Ra parameter underwent statistic analysis. The calculations were conducted by Statistica software.
PL
Urabiając (frezując) próbę cementowo-piaskową nożem styczno-ohrotowym mierzono i rejestrowano składowe siły oporu skrawania oraz masę urobku. W czasie urabiania zmieniano skokowo wartości parametrów skrawania (głębokość, podziałka skrawania) oraz rodzaj skrawania (otwierający, półotwarty). Pomiary przeprowadzono dla trzech ustawień noża styczno-obrotowego wynikających z j ego pozycji na frezującym organie ślimakowym. Opracowanie rezultatów badań oraz ich analiza pozwoliły na ustalenie wpływu parametrów skrawania i ustawienia noża na wartość oporów i energii urabiania.
EN
The paper presents results of research and analysis influence of cutting parameters and tool settings on resistance and energy of mining. Measurements were preformed with tangential-rotational bit.
EN
The synergistic effect of prepared tool edge and cutting parameters in hard whirling is still unclear, limiting its application in producing large precision ball screws. This paper aims to reveal the effect mechanism of cutting parameters and edge geometries in the whirling process to improve the stability of ball screw quality. A novel cutting force measurement strategy is proposed, and a systematic study of cutting force, surface quality and tool wear is implemented. The results show that small feed (less than 0.15 mm) and high cutting speed (more than 180 m/min) can ensure machining efficiency and improve surface quality. The machining quality can be improved when the edge radius is 10 µm, and the chamfer size is 0.1 mm × 20◦ . The tool with a 30 µm edge radius has a low probability of early failure, but the later wear is severe and timely sharpening is recommended. This study could guide cutting parameters and edge geometry optimization to improve the stability of the quality in hard whirling.
EN
One of the greatest problems of modern production techniques is the achievement of an appropriate quality at minimal costs and accompanied by the production efficiency increase. Therefore, while designing the production process. The technology used should have a considerable influence on the durability and reliability of machine parts to be produced. During finish treatment, the final dimensions as well as functional properties are imparted to a given element by application of proper treatment type. The engineer has a range of production techniques to choose for the proper surface layer formation. Conventional turning machines belong to the basic equipment of ships, because in sea conditions, they enable the execution of a spare part or carrying out the necessary operations in the process of their regeneration. The use of modern cutting tools makes it possible to obtain a surface with low values of surface roughness parameters. The use of new generation cutting inserts on conventional lathes can cause problems for operators. The lack of the ability to ensure proper of treatment condition and setting errors of cutting tools contribute to the damage of the cutting insert or the surface of the workpiece. The article presents the results of influence of different cutting parameters on surface topography during turning process of stainless steel. A shaft made of 304L stainless steel was used for the research. The cutting process was carried out on a universal TUM 25B x 500 centre lathes. During the turning the following machining parameters were used: cutting speed Vc [m/min], feed f [mm/rev] and depth of cut ap [mm].The turning process was conducted by a cutting tool with CCGT 09T302 UM, CCGT 09T304 UM and CCGT 09T308 UM inserts. Measurement of surface topography was carried out by T8000 profilometer.
EN
The paper describes micromilling machine and implemented sensor system for microcutting operations. Sensor system can be used for cutting forces, accelerations, acoustic pressure and tool displacements measurement. Cutting forces and accelerations signals were used for cutting depth, hardness of workpiece and excitation frequency of rotating tool monitoring. Other signals obtained during experiment will be used in further work. Conclusions arising from performed experiment and further research plans are presented.
8
Content available remote Effect of cutting parameters on chip formation in orthogonal cutting
88%
EN
Purpose: of this paper is to study the chip formation to obtain the optimal cutting conditions and to observe the different chip formation mechanisms. Analysis of machining of a hardened alloy, X160CrMoV12-1 (cold work steel: AISI D2 with a ferritic and cementite matrix and coarse primary carbides), showed that there are relationships between the chip geometry, cutting conditions and the different micrographs under different metallurgical states. Design/methodology/approach: Machining of hardened alloys has some metallurgical and mechanical difficulties even if many successful processes have been increasingly developed. A lot of study has been carried out on this subject, however only with modest progress showing specific results concerning the real efficiency of chip formation. Hence, some crucial questions remain unanswered: the evolution of white layers produced during progressive tool flank wear in dry hard turning and to correlate this with the surface integrity of the machined surface. For the experimental study here, various cutting speeds and feed rates have been applied on the work material. Findings: The “saw-tooth type chips” geometry has been examined and a specific attention was given to the chip samples that were metallographically processed and observed under scanning electronic microscope (SEM) to determine if white layers are present. Research limitations/implications: This research will be followed by a detail modelling and need more experimental results for a given a good prediction of the results occurred on the damage related to the microstructure by using the cutting parameters. Practical implications: A special detail was given to the mechanism of chip formation resulting from hard machining process and behaviour of steel at different metallurgical states on the material during the case of annealing and or the case of quench operations. Originality/value: For the sake of simplicity, ANOVA (Analysis of Variance) was used to determine the influence of cutting parameters. It gives a practical and useful tool for the machining in the industrial operations.
9
Content available remote Wpływ parametrów obróbki EDM na stan warstwy wierzchniej
88%
PL
W referacie zostały przedstawione kompleksowe badania stanu warstwy wierzchniej po obróbce elektroerozyjnej. Wyniki obejmują analizę wpływu podstawowych parametrów procesu na: mikrostrukturę geometryczną powierzchni, grubość warstwy wierzchniej, rozkład mikrotwardości, analizę i liczbę mikropęknięć oraz analizę wpływu parametrów obróbki na wydajność procesu EDM.
EN
The paper presents complex investigations on surface layer condition after the electrodischarge machining. The paper includes analysis of influence of basic process parameters on the EDM process characteristics such as geometric surface microstructure, surface layer thickness, microhardness distribution, analysis and number of microcracks as well as influence of the EDM process parameters on its efficiency.
EN
The paper describes the effect of cutting parameters and tool geometry on the surface quality after machining of an Al/CFRP (aluminium alloy/ Carbon Fibre Reinforced Plastics) sandwich structure. A two-layer sandwich structure made of an EN AW 2024 aluminium alloy and Carbon Fibre Reinforced Plastics (CFRP) was examined. The experiment used the process of peripheral milling. The experiment investigated the effects of cutting speed (vc), feed per blade (fz) and helix angle (λs) on surface quality as defined by differences in the height of materials. It was also analysed how the machining conditions described above affected the values of cutting force components. In the experimental stage of the study, uncoated, double-bit carbide mill cutters with working diameter Dc = 12mm and a variable helix angle (λs = 20˚, λs = 35˚, λs = 45˚) were used. The results have shown that cutting parameters and tool geometry do affect the surface quality and cutting forces after milling of the sandwich structure. The lowest material height difference was achieved when machining with the helix angle λs = 45˚, cutting speed vc = 300m/min and feed per blade fz = 0.08mm/blade. The highest material height difference occurred after machining under the following conditions: vc = 300m/min, fz = 0.08mm/min, λs = 20˚. The minimum cutting force value was obtained for cutting parameters: vc = 80m/min, fz = 0.08mm/blade during milling with the helix angle λs = 45˚. The maximum cutting force was recorded during machining with the helix angle λs = 20˚, cutting speed vc = 400m/min and feed per blade fz = 0.08 mm/blade.
EN
Nowadays acoustic emission (AE) method is used in many fields of science, including in the diagnosis of machining processes such as turning, grinding, milling, etc. Determining of turning parameters has a great impact on the quality of the surface. This is especially important during finishing treatment. In the study of acoustic emission, method was used to optimize the cutting depth. Optimization was to determine the depth of cut, at which the vibration level exceeds the set level. The research was carried out on a universal CDS 6250 BX-1000 lathe centre using dynamometer DKM 2010 where assembled removable insert CCMT 09 T304 PF. Lathing process was performed on the shaft of 40 mm in diameter made of S235JR steel. The research was carried out at constant cutting speed v = 145 m/min and at constant feed f = 0.114 mm/rev. In the research was used a set of acoustic emission Vallen System. The kit includes: 4 channel signal recorder AMSY 6, two measurement modules ASIP-2/S, preamplifier with a frequency range 20 kHz – 1 MHz and the strengthening of 34 dB and AE signal measurement sensor type VS 150M, with a frequency range 100 – 450 kHz. During the study, the acoustic emission (AE) generated during the lathing process was recorded parameters: amplitude, number of events – hits, the effective value of the signal (RMS). Analysis of the research results allowed to determine the maximum depth of cut, at which the vibration does not reach the set limit value. The study can be the basis for the use of acoustic emission method to determine the parameters of the finishing lathing for obtaining a high quality surface.
RU
Влияние параметров резания на качество обработки в процессе сверления отверстий в ламинированной ДСП (с использованием вертикального обрабатывающего центра с ЧПУ). Целью работы было определение влияния параметров резания на качество обработки в процессе сверления отверстий в ламинированной ДСП с использованием вертикального обрабатывающего центра с числовым программным управлением (ЧПУ) и только одним держателем, зажимающим заготовку снизу. Инструмент – сверло диаметром 15 мм. Эксперимент проводился при скорости вращения шпинделя 5000 об/мин. Рассмотрены три значения скорости подачи: 1,6 м/мин, 4,8 м/мин и 9,6 м/мин. В ходе испытаний, в каждом образце, были выполнены серии глухих отверстий в 5 рядах. Ряды были расположены на следующих расстояниях от нижней части заготовки: 50 мм, 225 мм, 400 мм, 575 мм и 750 мм. Качество полученных отверстий было определено максимальным диаметром (Dmax). В результате эксперимента ожидалось ухудшение при сверлении отверстий в верхних частях плиты. Анализируя результаты, было обнаружено, что худшее качество было получено на высоте 225 мм и 575 мм от нижнего края плиты.
PL
Wpływ parametrów skrawania na jakość obróbki podczas procesu wiercenia otworów w płycie wiórowej laminowanej (z zastosowaniem pionowego centrum obróbczego CNC). Celem artykułu było przeanalizowanie wpływu parametrów skrawania na jakość obróbki podczas wiercenia w płycie wiórowej laminowanej z zastosowaniem pionowego centrum obróbczego z jednym uchwytem mocującym obrabiany przedmiot od dołu. Narzędzie - wiertło o średnicy 15 mm. Eksperyment prowadzono ze stałą prędkością obrotową wrzeciona dla 3 wartości posuwu. W badanych próbkach wykonywano serie nieprzelotowych otworów w 5 rzędach oddalonych od elementu mocującego obrabiarki o 50 mm, 225 mm, 400 mm, 575 mm oraz 750 mm. Jakość otworów ustalono poprzez pomiar maksymalnej średnicy Dmax. W wyniku przeprowadzonego eksperymentu spodziewano się obniżenia jakości podczas wiercenia otworów w wyższych częściach formatki. Najniższą jakość uzyskano jednak na wysokości 225 mm oraz 575 mm od dolnej krawędzi elementów.
EN
In the present work, the performance of multilayer coated carbide tool was investigated considering the effect of cutting parameters during turning of 34CrMo4 Low alloy steel. It has high strength and creep strength, and good impact tenacity at low temperature. It can work at –110°C to 500°C. And EN 10083-1 34CrMo4 owns high static strength, impact tenacity, fatigue resistance, and hardenability; without overheating tendencies. The objective functions were selected in relation to the parameters of the cutting process: surface roughness criteria. The correlations between the cutting parameters and performance measures, like surface roughness, were established by multiple linear regression models. Highly significant parameters were determined by performing an Analysis of variance (ANOVA). During the experiments flank wear, cutting force and surface roughness value were measured throughout the tool life. The results have been compared with dry and wet-cooled turning. Analysis of variance factors of design and their interactions were studied for their significance. Finally, a model using multiple regression analysis between cutting speed, fee rate and depth of cut with the tool life was established.
EN
The paper presents influence cutting parameter to energy capacity cast iron. The study permitted to establish a strategy for energy saving.
PL
Celem przeprowadzonych badań było określenie wpływu parametrów skrawania na jakość powierzchni obrobionej podczas toczenia wzdłużnego superstopu Inconel 718 bez udziału cieczy chłodząco-smarującej. Zrealizowane badania posłużyły do określenia częstotliwości powstawania narostu (oblepień) na obrobionej powierzchni podczas obróbki na sucho. Uzyskane wyniki pokazują, że podczas obróbki stopów na osnowie niklu bez udziału cieczy chłodząco-smarującej najkorzystniej jest stosować większe głębokości skrawania i większe wartości posuwu. Podczas przeprowadzonych badań najmniejsze wartości częstotliwości powstawania narostu na powierzchni obrobionej otrzymano przy zastosowaniu najwyższych parametrów skrawania podczas prób, tj. f = 0,21 mm/obr. i ap = 0,3 mm. Z kolei najwyższe wartości częstotliwości powstawania narostu na powierzchni obrobionej otrzymano podczas skrawania z najmniejszymi parametrami, tj. f = 0,05 mm/obr. i ap = 0,05 mm. Rezultaty badań pokazują relację minimalnej grubości warstwy skrawanej z wartością promienia zaokrąglenia krawędzi skrawającej. Uwidacznia się to zwłaszcza przy małych przekrojach warstwy skrawanej.
EN
The aim of the research was to determine the effect of cutting parameters on the surface quality of Inconel 718 super alloy during longitudinal turning without the use of a lubricant. Completed research was used to determine the frequency of the accretion on the machined surface during dry turning. The results show that during machining of nickel based alloys without using a lubricant, it is preferable to use larger cutting depths and higher feed rates. During the tests, the smallest values of the frequency of accretion on the machined surface were obtained using the highest cutting parameters during the tests, ie. f = 0.21 mm/rev. and ap = 0.3 mm. Whereas the highest values of the frequency of accretion on the machined surface were obtained during the cutting with the lowest parameters, ie. f = 0.05 mm/rev. and ap = 0.05 mm. The results of the study show the relation of the minimum thickness of the cutting layer to the radius on the cutting edge. This is especially visible with small cross-section of the cutting layer.
EN
Nowadays acoustic emission (AE) method is used in many fields of science, including in the diagnosis and monitoring of machining processes such as turning, grinding, milling, etc. Monitoring of turning process allows ensuring stable conditions of treatment. Stable conditions of turning process have a great impact on the quality of the surface. This is especially important during finishing treatment. The research was carried out on a universal ZMM-SLIVEN CU500MRD lathe centre-using tool with removable insert SANDVIK Coromant WNMG 080408 – WMX Wiper. Lathing process was performed on the shaft of 74 mm in diameter made of S235 steel. The research was carried out at constant cutting speed v = 230 m/min. Changed parameters were feed f = 0.1; 0.2; 0.4 mm/rev and cutting depth ap = 0.5; 0.75; 1 mm. In the research was used a set of acoustic emission Vallen System. The kit includes: 4 channel signal recorder AMSY 6, two measurement modules ASIP-2/S, preamplifier with a frequency range 20 kHz – 1 MHz and the strengthening of 34dB and AE signal measurement sensor type VS 150M, with a frequency range 100 – 450 kHz. During the study, the acoustic emission (AE) generated during the lathing process were recorded parameters e.g. amplitude, number of events – hits, the effective value of the signal (RMS). The test results indicate, that the higher instability of the process was during turning with parameters: ap = 0.75 mm and f = 0.1 mm/rev. The study can be the basis for the use of acoustic emission method for monitoring lathing process to ensure stable conditions of that process and the same to obtain a high quality surface.
18
Content available remote Optymalizacja programów obróbczych na obrabiarkach CNC
75%
PL
W artykule podjęto próbę zrozumienia wpływu parametrów obróbki, takich jak: prędkość skrawania (m/min), prędkość posuwu (mm/min), głębokość skrawania (mm), które mają istotny wpływ na takie parametry wyjściowe jak chropowatość powierzchni i objętościowa wydajność skrawania osiągnięta w wyniku procesu optymalizacji.
EN
The paper attempts to explain the effect of machining parameters, such as cutting speed (m/min), feed rate (mm/min), cutting depth (mm), which have a significant impact on such output parameters as surface roughness and volume machining efficiency achieved as a result of the optimization process.
PL
Przedstawiano wyniki badań dotyczące wpływu trzech czynników wejściowych o trzech stopniach wartości kodowych, takich jak prędkość posuwu głowicy tnącej, odległość końca dyszy wodno-ściernej od ciętego materiału i wydatek dozowanego ścierniwa na wartość wyjściową, którą była odchyłka okrągłości mierzona w trzech przekrojach. Otwory zostały wycięte w stopie aluminium za pomocą wysokociśnieniowej strugi wodnej z dodatkiem ścierniwa.
EN
This paper discusses experimental results concerning the geometric accuracy of cylindrical holes. The input variables were the cutting speed, the distance between the abrasive water jet nozzle and the workpiece, and the abrasive mass flow rate. The output variables were roundness deviation, which were measured in three sections. The holes were made in aluminum alloy by a high-pressure jet of water containing almandine garnet as an abrasive substance.
20
Content available remote Dobór parametrów skrawania tej samej części dla różnych strategii obróbki
75%
PL
Programowanie obrabiarek CNC za pomocą programów CAM umożliwia szybkie projektowanie różnych wariantów obróbki tej samej części. Wybór najlepszego rozwiązania wymaga porównania wyników obróbki na etapie symulacji procesu. Czas symulowanej obróbki jest jednym z najważniejszych kryteriów wyboru. Aby uzyskać wiarygodne wyniki symulacji czasu obróbki, trzeba ustawić parametry obróbki zbliżone do rzeczywistej realizacji na maszynie. W artykule zaproponowano modyfikację danych katalogowych doboru parametrów skrawania w oparciu o wcześniej realizowaną obróbkę.
EN
CNC machines programming based on CAM programs make possible fast preparing different strategies machining for the same part. A choice of the best way needs simulation processes comparison. The simulation of machining needs suitable cutting parameters defined. In the article modification of standard cutting parameters concerning to previous machining is proposed.
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