The impact of friction factor, thickness of the cold extrusion, semi-cone angle and other factors on cold extrusion was analyzed. Various process parameters were set and optimized. Cold extrusion process of hollow pieces was simulated by DEFORM-3D software. Through the simulation of the virtual velocity field, strain field, stress field, load - stroke curve and metal deformation process, the flow velocity of the metal and the deformation of the workpiece were studied. The metal flow routes and the parts that are easy to wear in die were gained. The above research results provide valuable references for the processing of hollow pieces.
In order to study the physical nature and basic rule of diamond wire saw slicing SiCp-Al composites, the slicing mechanism was studied in theory first. There are different ways of slicing Al and SiC particles respectively: Al is sliced in plastic way and SiC particles are sliced in brittle ways such as being cut off or pulled out or pressed into matrix or burst. Then based on the finite element software Abaqus, the process of diamond wire saw slicing SiCp-Al composites was simulated. The distribution of internal stress and surface topography was discussed: The internal stress in SiC particles is far high than that in Al. The surface topography of sliced SiCp-Al composites is determined by SiC particles states mainly. The research results provide reference and guidance to the optimization of actual process of diamond wire saw slicing SiCp-Al composites.
Based on the 3D finite element simulation software DEFORM-3D V6.1, the cutting process of three kinds of typical hard processing materials (titanium alloy, nickel alloy, stainless steel materials) were simulated. Main cutting force and cutting temperature of above materials were observed at different cutting parameters and cutting performance was studied. Results show that: under the same conditions, the main cutting force of nickel alloy IN718 was maximum, followed by TI-6AL-4V titanium alloy, stainless steel AISI-316h was minimum; the cutting temperature of nickel alloy IN718 was the highest, followed by TI-6AL-4V titanium alloy, stainless steel AISI-316h was minimum.
To analysis cutting mechanism and heat transfer coefficient of Ni-based superalloy IN718, this paper introduced a three-dimensional finite element model for cutting process based on DEFORM-3D V6.1, and cutting force Fy and cutting temperature T under different feed rate f , cutting speed v and back engagement ap were obtained. The temperature variation during cutting process under different cooling method was analyzed. The simulation results indicate that the influence of back engagement ap on the cutting force Fy is the greatest, while that of cutting speed v is minor; and for cutting temperature T, influence of cutting speed v is the greatest, while that of back engagement ap is minor. Influence of heat transfer coefficient on highest temperature and average cutting force Fy is minor, but its influence on average temperature is quite obvious. Greater heat transfer coefficient is less average temperature.
In order to study the basic rule of diamond wire saw slicing SiCp-Al composites, the theoretical analysis and experiments were carried out. The influences of diamond wire saw slicing speed and workpiece feed speed on surface quality and machining efficiency were discussed. The analysis results show that the machined surface gets smoother when diamond wire saw slicing speed changes from 2m/s to 3.5m/s, but gets rougher when diamond wire saw slicing speed changes from 3.5m/s to 4m/s. And the surface gets rougher when workpiece feed speed changes from 0.5m/s to 1m/s.The machining efficiency gets higher when diamond wire saw slicing speed and workpiece feed speed increase. These results provide guidance for selecting reasonable parameters in future research.
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