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Modified Power Prediction Model Based on Infinitesimal Cutting Force during Face Milling Process
Xiaona Luan,Song Zhang,Gang Li 한국정밀공학회 2018 International Journal of Precision Engineering and Vol.5 No.1
Nowadays soaring energy price, increasing environmental concerns, and stringent legislations make energy saving very emergency and helpful both for enterprises and environment. To deal with these issues, this paper presents a generalized mathematical power prediction model of face milling process used in manufacturing. An attempt was made to develop a relatively precise and direct power consumption model to help researchers make power optimization much easier and more practical than before. First, an infinitesimal cutting force model was proposed based on theoretical and experimental foundations. Secondly, relationship between power consumption and cutting force components was revealed, and power consumption based on infinitesimal cutting forces during metal removal process was developed. Finally, the proposed model was experimentally verified by comparing predicted and measured power consumption. Both average and instantaneous values of power consumption were used to analyze prediction error of the model. This proposed model can be used to evaluate and optimize cutting power consumption once cutting parameters were decided based on minimal energy demand. Results showed that the mean errors of maximum power and mean power were 0.076% and 0.208%, respectively. Otherwise, this proposed model will drive the field of power consumption simulation development.
Residual Stresses of α-Al2O3/Ni Nano-Composite Coating Prepared by Automatic Brush Plating Technique
Jia Man,Song Zhang,Xiaona Luan,Yuan Hai,Gaoli Cai 한국정밀공학회 2017 International Journal of Precision Engineering and Vol.4 No.1
Brush plating is one of the remanufacturing technologies which have been widely used in engine remanufacturing. In this paper, α-Al2O3/Ni composite coatings were prepared on the inner hole face of the big end of connecting rod by a self-made automatic plating machine. To investigate the effects of process parameters on residual stresses of α-Al2O3/Ni composite coating, a L16(44) orthogonal experiment was designed and operated in which four process parameters (voltage, concentration of α-Al2O3 particles, speed, and distance between anode and workpiece) were selected as factors. ANOVA (analysis of variance) were employed to determine the effects of process parameters on the residual stresses of composite coatings. It was found that speed was the most significant factor for the residual stresses. The optimal process parameters for the desirable residual stresses were obtained, which was proved to be valid by the verification experiments. In addition, single factor experiments were employed to study the main effects of process parameters on composite coatings.