From the perspective of clean production process, this paper summarizes the present research status of green cooling machining at home and abroad and analyzes the problems of coolant cooling during machining metal materials in traditional method and. The green cutting process tests using water vapor for cooling lubricant were done and the single-factor method was used. The cutting tests for the high-temperature alloy GH4169, titanium alloy TC4 and stainless steel Cr12 were done by the carbide cutting toolsunder th condition of distilled water, emulsion, water vapor for cooling lubricant and dry cutting. These tests results showed that in same process parameters, main cutting force Fc can be reduced by about 30%, 26% and 22% respectively when using water vapor for cooling lubricant than using dry cutting, distilled water and emulsion, while the cutting temperature T can be decreased by about 12%, 6% and 3% respectively.
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.
The chemical composition and properties of nickel-based superalloy Inconel 718 was investigated first. Turning Inconel 718 was simulated by Deform-3D software to figure out main affection factors, and optimal combination of cutting speed, feed rate and cutting depth was introduced. In addition, different cooling and Lubrication methods (heat transfer coefficient f of cooling and tool-chip friction factors) for cutting of Inconel 718 was studied, and a best cooling/lub mode was obtained.
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.
For solving the crack in crankshaft, laser cladding remanufacturing was involved. There were three key points about laser cladding remanufacturing discussed in this paper.The three key points included process flow , process environment and laser cladding materials selection . Using the ANSYS analysis software, the simulated analysis of the temperature field , stress field and the residual stress of the three kinds of cladding layer have been carried on, the best cladding materials for single-throw crankshaft crack of base material 45# is determined by studying the repaired results about Iron-based,Cobalt-based,Nickel-based self-fluxing alloy powder cladding materials.
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