Electrical Heating Assisted Cutting And Process Monitoring

With the development of modern manufacturing industry step by step,a lot of hard processing material(e.g.,high temperature alloys,hardened steel,stainless steel,etc.)have been widely used in national defense,aerospace,automobile ship and some other important areas for its excellent physicochemical performance(e.g.,high strength,high hardness,corrosion resistance,etc.),but how to enable efficient and stable machining has become inevitable question in manufacturing field.Electrical heating assisted cutting is one of the effective method.Electrical heating assisted cutting is a new kind of machining method based on the theory of metal softening effect and phase change theory.it owns two independent electrode heating capacity,Rather than traditional electric heating assisted cutting in the form of cutting tools as electrode.Comparatively speaking,reducing the arc extinction device,increasing the heating stability and prolonging the tool life.Previous studies have proved that the certain feasibility of cutting difficult-to-machine materials.This paper mainly monitors cutting process from the cutting force,cutting temperature and cutting vibration,and its superiority is demonstrated.In this paper,it explores the processing mechanism of electrical heating assisted cutting,makes a qualitative analysis of heating principle and calorific value and sets up the heating resistance model of turning and milling,including the calculation of it,based on the learning traditional EHM(Electric Heating assisted Machining).Designing to building the car/milling experimental system,selecting 304 stainless steel and T10A hardening tool steel as the experimental object,and setting cutting parameters referring to the Metal cutting manual,formulating the general machining condition and extreme conditions for the result of comparing with each other,Using a self-designed acquisition system of cutting force,combining with the vibration,temperature sensors,synchronously gaining 3 signals,,cutting force,cutting temperature and cutting vibration,while data will be processed by WT(wavelet transform)based on MATLAB,comparatively analysising of the influence laws and mechanism of cutting parameters on cutting force and cutting vibration,finding out the temperature change rule in the process of experiment,afterwards,it sums up the optimal parameter combination.Later,observing the fore-and-aft microstructure of workpiece materials with SEM(Scanning Electron Microscopy)and concerning the microstructure changes.The experiment shows that cutting vibration is reduced by more than 150%,cutting force was reduced by 15%?30%,and the material base structure did not change significantly before and after processing,keeping the original chemicophysics properties by comparing the heating assisted cutting and traditional way of turning/milling.Carbon fiber composite materials(CFRP)depend on excellent material properties,such as high specific strength,high specific stiffness,corrosion resistance,light quality,fatigue resistance and so on,being widely used in aerospace field.It is difficultly machined by traditional process and the rejection rate is higher.This is the first time that the application of the method of electrical heating assisted cutting is used on CFRP in this paper,it explores the cutting mechanism,sets up the experimental system,verifies the feasibility of the method,studies processing phenomenon and law with different parameters,and observes material morphology structure in material-electrode contact region.finally,it appraises the composition and morphology of the residue on ignition.The experiments show that the method of electrical heating assisted cutting carbon fiber composite material is really feasible,heat damage on the material is not really obvious,the method almost does not affect the machining quality as long as setting aside appropriate cutting allowance in advance.The advantage of electric heating assisted cutting technology is that it can be widely used in general machine tools,high economic value,strong adaptability,simple operation,and has a broad development prospects.