Search results for " Machining"

Electroanalytical chemistry for the analysis of solids: Characterization and classification (IUPAC Technical Report)

2012

Solid state electroanalytical chemistry (SSEAC) deals with studies of the processes, materials, and methods specifically aimed to obtain analytical information (quantitative elemental composition, phase composition, structure information, and reactivity) on solid materials by means of electrochemical methods. The electrochemical characterization of solids is not only crucial for electrochemical applications of materials (e.g., in batteries, fuel cells, corrosion protection, electrochemical machining, etc.) but it lends itself also for providing analytical information on the structure and chemical and mineralogical composition of solid materials of all kinds such as metals and alloys, variou…

On Fixed Point (Trial) Methods for Free Boundary Problems

1992

In this note we consider the trial methods for solving steady state free boundary problems. For two test examples (electrochemical machining and continuous casting) we discuss the convergence of a fixed point method. Moreover, using the techniques of shape optimization we introduce a modification of the method, which gives us superlinear convergence rate. This is also confirmed numerically.

An Experimental Investigation of Residual Stresses in Hard Machining of AISI 52100 Steel

2011

In this paper an experimental investigation was conducted to determine the effects of the tool cutting-edge geometry, workpiece hardness, cutting speed, and microstructural changes (white and dark layers) on the residual stresses in dry orthogonal hard machining of AISI 52100 steel. X-ray diffraction technique was used to obtain in-depth residual stresses profiles in both axial and circumferential directions. The results show that tool geometry, workpiece hardness and cutting parameters significantly affect the surface residual stress, maximum compressive residual stress below the machined surface and its location. Moreover, microstructural analysis shows that thermally-induced phase transf…

On the finite element simulation of thermal phenomena in machining processes

2007

Machining processes are frequently investigated by numerical simulations. Usually 2D analyses are carried out in order to reduce CPU times, considering orthogonal cutting conditions. In this way, the computational time sharply reduces and many process variables may be calculated (i.e. forces, chip morphology, shear angle, contact length). On the other hand, the analysis of thermal aspects involved in machining, for instance the temperature distribution reached in tool, still represents an open problem. Finite element codes are able to simulate a very short process time that is not sufficient to reach steady state conditions. Several approaches have been proposed to overcome this problem: in…

Inverting Multiple Residual Stress Components from Multiple Cuts with the Contour Method

2007

An extension of the contour method is presented which allows the measurement of multiple stress components by making multiple cuts. In the contour method, a body is carefully cut in two using wire electric discharge machining (EDM). The contours, or shapes, of the cut surfaces are then measured and used to calculate the original residual stress normal to the cut plane using a simple finite element calculation. In the extension presented here, the two pieces from the original body can be cut again in a transverse direction, and the contours of the new cut surfaces are measured. The stresses calculated on the planes of these second cuts have been affected by the first cut. Then a simple inver…

Study Regarding Process of the Electrical Discharge Machining with Magnetic Activation of the Welded Joints of some Materials High Alloy Steel

2021

The scientific paper presents an extensive research on modeling and optimizing the technological parameters of the process for processing by processing electric discharges with massive electrode with and without magnetic activation. Scientific research is based on real data collected from the process of electrical discharges performed on various samples extracted from areas of welded joints of metal components made of high alloy steel. The processing of experimental data was performed both classically and actively, especially the method of the central factorial experiment composed of orthogonal and rotary. The process parameters that were initially modeled and subsequently optimized were ba…

Surface Integrity and Microstructural Phenomena of Ck 60 Steel Due to Electro-Discharge Machining

2006

Wiper Tools in Turning Finishing of Quenched Steel

2005

In the last years, the research on metal machining has been focused on the development of tools that can support an increment of the cutting parameters instead of the increment of tool life; this strategy is focused to obtain a relevant productivity increment without getting worse the final product quality. The new design of the tool corner radius has allowed preserving the same product quality due to the “wiper effect” generated during the cut. The employ of such re-designed tools can allow substantial productivity improvements and, by employing the same feedrate, it is possible to achieve excellent surface finish and eliminate the grinding operation. With the aim to verify the possibility…

Subtractive versus mass conserving metal shaping technologies: an environmental impact comparison

2015

The scientific studies in the domain of environmental sustainability of metal processing technologies predominantly focus on conventional material removal processes, as milling and turning. Despite some exceptions, many other non-machining technologies, such as metal forming processes, are still not well documented in terms of their energy and resource efficiency. Moreover, to properly evaluate the environmental impact of a given process, a standing-alone approach is no longer sufficient. In order to offer a valuable contribution in the domain of metal shaping sustainability, the present paper proposes a thorough methodology entailing to compare, from the environmental point of view, two tr…

Assessment of Cost and Energy Requirements of Electron Beam Melting (EBM) and Machining Processes

2017

Additive Manufacturing is under the spotlight as potential disruptive technology, particularly for the production of complex-shaped structural metallic components. However, the actual AM process capabilities present some limitations in achieving the strict part quality requirements imposed by the aerospace and automotive sectors. Therefore, the integration of AM and conventional manufacturing represents an emerging scenario to be investigated. In this paper, a pure machining process and a hybrid production route (based on EBM and finish machining) are compared. The influence of material usage-related factors on costs and energy demand is discussed. The results prove that, despite precise pr…