基于集成神经网络的刀具磨损量监测

提出了一种基于集成神经网络识别铣刀磨损量的监测方法．利用小波包变换将切削力和振动信号分解为不同频带的时间序列，从每个信号中选择与刀具磨损状态最相关的3组频段的均方根作为监测特征；通过信号的组合和不同子网络输出决策间的融合，集成神经网络输出刀具磨损的识别结果．试验和仿真分析表明，此方法能够满足刀具磨损量实时监测的要求．     

Tool Wear Prediction in Micro-end-milling with Hard Material

The applications of micro-machining have increased drastically in the last ten years. However, tools with less than 1mm diameter using for micro-mills have very short and unpredictable life when they are used to cut hard metals. In this study, preliminary design of experiment (DOE) test program was conducted to investigate and identify the factors affecting tool wear at the micro-scale with hard material. Analysis of variance (ANOVA) and Taguchi method were efficient to determine appropriate cutting condition and the effect of parameters. A simple model was also developed to predict the width of slots on the workpiece along the cutting length. The obtained results can provide the basic guidelines for parameter setting of micro-end-milling with hard material.     

Fabrication and drilling tests of chemical vapor deposition diamond coated drills in machining carbon fiber reinforced plastics

Chemical vapor deposition (CVD) diamond coated drills are fabricated by depositing diamond films on Co-cemented tungsten carbide (WC-Co) drills. The characteristics of as-deposited diamond coatings are investigated by scanning electron microscope (SEM) and Raman spectra. To evaluate the cutting performance of diamond coated drills, comparative drilling tests are conducted using diamond coated and uncoated WC-Co drills, with carbon fiber reinforced plastics (CFRPs) as the workpiece on a high-speed computer numerical control (CNC) machine. Thrust force and tool wear are measured during the drilling process. The results show that diamond coated drill exhibits better cutting performance, compared with the uncoated drill. The value of flank wear is about 70 μm after machining 90 holes, about a half of that of theWC-Co drill with 145μm after drilling only 30 holes. The wear rate of WC-Co drill is higher than that of diamond coated drill before diamond films peeling off. The diamond coated drill achieves more predictable hole quality. The improved cutting performance of the diamond coated drill is due to the high hardness, wear resistance and low coefficient of friction.     

INVESTIGATION ON FRACTAL CHARACTERISTICS OF WORN SURFACES OF POLYMER TAPES BY SAND DUST PARTICLES

Objective To characterize the abrasive wear of polymer tapes in ATM （Auto Teller Machine） servicing in sand dust environment. Aethods The abrasive wear experiment of polymer tapes, PEN （polyethylene-2, 6-naphthalenedicarboxylate） and PI （polyimide）, by sand dust particles is performed in ATM tribosystem. The fractal characteristics of the worn surface of polymer tapes and the corresponding wear mechanisms are examined. ReSults As main results, the worn surfaces of polymer tapes show bi-fractal characteristics, and PI tape shows higher fractal dimensions and finer wear profiles than PEN tape. Wear mechanism examination shows macro and micro ploughing and cutting grooves and micro fracture characters, which gives reasonable explanation of bi-fractal character of worn polymer tapes. Conclusion Worn polymer tape shows fractal character and bi-fractal can be used in accurately characterizing the abrasive wear of polymer tapes of ATM in sand dust environment.     

新构形齿轮精加工刀具半径对切齿干涉的影响

新构形齿轮精加工刀具采用新切齿法,具有连续的切削刃,使得切齿过程中无冲击,刀具的制造和刃磨都非常简单.新构形刀具的半径对切齿干涉的影响较大,因此要合理设计刀具半径,避免干涉.根据该刀具的切齿原理,分析了齿廓曲面上各点在切齿过程中的轨迹和切削刃曲线,并将其向齿轮的的端截面内投影,发现齿顶处的干涉最严重;通过比较齿顶轨迹与切削刃的位置关系,研究了切直齿轮和斜齿轮时刀具半径的干涉,得到了统一的刀具半径干涉的理论公式,确定了不发生切齿干涉的最小刀具半径值,并给出了一个具体的设计实例.     

耐磨钢NM360的耐磨性能试验研究

NM360是在Q345基础上通过调整合金元素后生产的新钢种。还缺少摩擦磨损性能的评定参数，通过粘着磨损和冲蚀磨损试验用称重法测量其磨损量，测定了它的抗粘着和抗冲蚀的摩擦学性能，试验结果表明微量合金元素能改善材料组织，其性能优于Q345。并与国外同类产品的性能相当．     

脉冲强磁场处理高速钢刀具磨损机理的探讨

本文研究了用高速钢车刀切削45钢时,脉冲强磁场处理减小刀具磨损的机理:研究了磁化场强度及切削速度对刀具磨损的影响;考察了硬度及金相显微组织的变化;证明了在脉冲强磁场处理下,刀具材料强化的主要原因是碳化物的弥散析出所导致的弥散硬化效果的作用.     

磨损试验中的切入法数据处理

本文主要介绍用M－200磨损试验机进行试验时，采用切入法对试件的磨损量进行分析处理，以比较材料的耐磨性能，并提供实用性数据。     

气缸套内表面磨损的图像处理检测方法研究

对柴油机内表面磨损的特征和机理进行了研究，对图像边缘提取的经典算法（梯度算子和拉普拉斯算子等）和小波变换算法进行了分析与比较，提出了用图像处理的方法实现气缸套内表面磨损检测的途径．     

机夹刀片断屑范围预报及最佳断屑槽形设计

本文在研究金属切削过程中的切屑变形、流动、流向与切屑卷曲、折断等规律的基础上.提出一种新的切屑分类,便于通过计算机求得屑形,用以预报断屑范围.同时,又能设计出特定条件下的最佳情形.     

轨道车辆新型车端专用吸能装置

为了提高轨道车辆的耐碰撞性,利用金属薄壁结构轴向切削和压缩过程吸收能量的原理,设计了一种新型车辆端部专用吸能装置;采用显式有限元软件LS-DYNA建立了吸能装置吸能过程的等效三维有限元模型,并对吸能过程进行数值模拟;分析了切削深度、刀具前角和切屑圆心角等参数对吸能装置吸能性能的影响.研究结果表明,新型吸能装置吸收的能量、界面力与切削深度、切屑圆心角成正比,与刀具前角成反比,受切削深度的影响较小;新型吸能装置的冲程效率可达100%,压缩力效率和总效率可达70%以上,高于现有吸能装置.      

角接触球轴承微动磨损行为

为了解载荷、摆动角度和循环次数对角接触球轴承微动磨损行为的影响,用自制的轴承微动试验装置对角接触球轴承QJ208在干态下进行了3种摆角(0.88°、1.21°和1.54°)、4种轴向载荷(2.5、5.0、10.0和20.0 kN)、2种循环次数(2和12万次)的摆动微动试验,在此基础上,对轴承磨痕进行分析.结果表明:外圈上微动磨损随载荷增大而减缓,随摆角增大而加重,随循环次数的增加,其磨损增幅趋缓;在摆角为0.88°时,磨损机制以疲劳磨损为主,在摆角为1.54°时,则以磨粒磨损为主;在同一钢球接触处,外圈上的磨痕比内圈上的磨痕严重.     

摩擦条件对钢质摩擦材料第三体及磨损的影响

摩擦条件对摩擦材料表面第三体的连续性产生重要影响,进而影响材料的摩擦磨损性能.选用两种轨道车辆用低合金制动盘材料与铜基粉末冶金材料为配对摩擦副,在不同速度、压力条件下进行摩擦试验,观察第三体的形成过程中,表面形貌的变化规律及磨损机理.结果表明：在特定的摩擦条件下,第三体的显微硬度可达800~900HV,远高于基体材料的硬度;连续、致密的第三体,使材料具有最低的磨损率;当摩擦转速和压力过低时,磨粒磨损为主要磨损形式,当摩擦转速和压力过高时,黏着磨损将成为主导;在第三体的形成破坏过程中,摩擦速度、压力过低或过高均可能使第三体的破坏速度大于形成速度,使材料的磨损率增大.     

TiN和TiC涂层车刀性能的试验分析

文章介绍了涂层刀具与未涂层刀具在切削加工中的性能比较及试验分析。从不重磨车刀的使用寿命、加工表面粗糙度等方面 ,来展开试验分析研究。     

小半径曲线上的钢轨磨耗

本文概述了小半径曲线上钢轨侧面磨耗的典型现象；分析了形成严重侧磨的原因；描述了侧磨的三个阶段及其判别方法；讨论了磨耗因子的选用条件；提出了减缓侧磨的技术措施并重点叙述了合理设置轨道参数在减磨中的作用。     

人工关节磨损测量方法综述

人工关节的磨损问题是制约我国人工关节矫形术全面开展的重要因素之一，而磨损的检测和分析技术是评价磨损的手段。随着新技术、新材料等的发展，对人工关节磨损的检测提出新的要求，其中越来越迫切需要精确实现人工关节微量磨损的数字化检测、分析和表征。文章论述了目前国内外主要测量方法，分析了各自的特点和优点，这对于人工关节磨损的测量及其研究具有参考价值。     

渐开线齿轮磨损的数值仿真

建立了渐开线齿轮磨损的数值仿真模型,开发了计算动态磨损过程的软件,可计算齿轮磨损量的渐变过程与所经历时间之间的关系。实现了齿轮磨损动态仿真的预期目标。     

Effects on Microstructure and Properties of Brass Treated by Laser Shock Processing

Laser shock processing （LSP） has been proposed as a new surface treatment for improving hardness, wear resistance and fatigue. In this paper, the effect of LSP on brass is investigated with experiment. Micro-hardness, roughness, microstructure, wear resistance and friction coefficient evolution are investigated for different parameters of LSP. The result shows that the roughness increases after LSP; no ablation is observed; the microstructure has no remarkable ehange; hardness and the wear resistance increase as the pulse density increases.     

Friction characteristics in green drilling titanium alloy Ti6Al4V

Titanium alloy Ti6Al4V, as difficult-to-cut material, has poor machinability. Conventional cutting fluid serves as a coolant and lubricant. In green drilling, water vapor is recognized as an effective coolant; however, its lubrication properties are not well known in drilling. This paper investigates the friction characteristics between chip and tool in green drilling Ti6Al4V, compared with that in sliding and turning process. A friction evaluation model is developed based on the equivalent model of drilling, then is used to calculate the effective friction coefficient. Results indicate that the friction coefficient on the tool-chip interface is considerably reduced in drilling by water vapor, so the drilling forces decrease, too. The friction coefficient decreases as velocity increases in drilling, which is different from the law of sliding tests; the friction coefficient increases when the distance to chisel edge increases.     

Dry milling of the ultra-high-strength steel 30CrMnSiNi2A with coated carbide inserts

The ultra-high-strength steel (UHSS) plays an important role in the mechanical industry because of their special performances. The machinability of 30CrMnSiNi2A steel was studied in dry milling with two different coated tools in the present work. This paper introduced that 30CrMnSiNi2A steel was a kind of difficult-to-machine materials. The results showed that the cutting force components of feed direction and cutting width direction, i.e. F x and F y , increased slightly with increasing the cutting speed and feed rate. The values of axial force component F z were much larger than F x and F y , and increased obviously with increasing the milling speed. The workpiece surface had the minimum roughness at the cutting speed of 150 m/min. The physical vapor deposition (PVD) coated ((Ti, Al)N-TiN) insert was more suitable for machining 30CrMnSiNi2A steel than the chemical vapor deposition (CVD) coated (Ti(C, N)-Al 2 O 3 ) insert. Moreover, the main failure modes of PVD-coated insert were micro-chipping and coating spalling. The wear modes of CVD-coated insert were ploughing, coating spalling, and cratering. The serious adhesive wear and the abrasion with some adhesion were the main wear mechanism of PVD- and CVD-coated inserts, respectively.