Engineering ceramics have been extensively used as structural materials in modern manufacturing industries due to their excellent properties. High Efficiency Deep Grinding (HEDG) with Electrolytic In-process Dressing (ELID) process can realize the stabilized and controlled grinding process of engineering ceramics, but there lies many questions to be done. In the light of Y-TZP materials, the grinding process of HEDG with ELID was optimized, and comparisons were made between HEDG with ELID and HEDG without ELID process for Y-TZP ceramics, and mechanisms of HEDG with ELID were revealed.
A novel non-keyhole friction stir welding technique was proposed to weld the butt joint of 6061-T6 aluminum alloy with the thickness of 6 mm. A sound joint was obtained by this technique, simultaneously eliminating the flash, shoulder mark and keyhole defects. The sleeve directly affected zone (SDAZ) and the sleeve indirectly affected zone (SIAZ) were divided into the joint according to the plunging position of the hollow sleeve. The lack of root penetration defect was avoided when the plunging depth of the hollow sleeve was only 4.2 mm, because the hollow part inside the sleeve improved the material flow below the sleeve. An S-shaped line was left at the SIAZ, and the height of it had the minimum value of 1.47 mm at 20 mm/ min. Whether the failure location of the joint was in SIAZ/SDAZ or the heat-affected zone (HAZ) depended on the height and bonding strength of the S-shaped line. The joint fracture location changed from the SIAZ/SDAZ at 35 mm/min to the HAZ at 20 and 30 mm/min. The maximum tensile strength of 224.3 MPa was obtained at 30 mm/min which was 73.7% of that of the base material. The fracture surface morphology exhibited the typical ductile fracture.
Copper-tungsten alloy which is widely used in the field of EDM has high melting temperature and excellent electrical and thermal conductivity. Copper tungsten electrodes for electrical discharge dressing of metal-bond wheel were studied, and experiments were conducted to observe their wear performance in this paper. Orthogonal experiment was designed to explore the wear at the edge of and the bottom of electrode with the machining of holes. Thickness of the carbon layer, micro topography and experimental results were analyzed. Low current and big pulse duration can reduce the electrode wear rate. Although carbon on the electrode surface can be wiped out easily, wear rate of copper-tungsten electrode decreases with the increasing in thickness of the carbon at the initial phase. There are fewer cracks and residue presented on the machined surface by microscope.
According to broken edges and cracks emerging in traditionally machining cemented carbides (CP1) materials, this paper carried out some experimental researches on high and ultra-high grinding process for these materials, and considered the effect of process parameters on grinding forces, surface roughness, surface quality; discusses the calculation of the single grinding average normals force and relationship with maximum undeformed chip thickness and theoretical critical normal loads; probes the removal mechanisms of cemented carbide in high/ultra-high grinding process.
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