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Due to the rapid development of the modern industry, people have higher and higher requirements on the rolling speed and quality of steel. The performance of conventional cast-iron roll cannot supply production demands because it contains higher chrome-nickel elements. The high-speed steel W6Mo5Cr4V2 with high service life, red hardness and wear re...
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The application of the minimum quantity lubrication (MQL) technique in grinding processes is still limited due to the frequent occurrence of overheating and wheel clogging. In this context, this research evaluates a cooled wheel cleaning jet (CWCJ) under different temperatures, applied simultaneously to MQL in the cylindrical grinding of AISI 4340...
Citations
... Table 1 lists the chemical composition of the A-286 superalloy. W6Mo5Cr4V2 steel, known for its high hardness, excellent wear resistance, and impact resistance, was chosen as the die material [25,26]. The clearance between the workpiece and the bottom die was 0.02 mm. ...
Cold forging is suitable for manufacturing thin-walled tubes; however, a poorly planned forging process results in serious quality problems. This paper aims to determine an appropriate cold forging process for thin-walled A286 superalloy tube with ideal forming quality. We analyzed the effects of the two forging processes with reverse forging sequences on forming defects and hardness distribution in the thin-walled tubes via finite element simulation. The methods of optical microscope, micro-hardness, scanning electron microscope, and electron-backscattered diffraction were used to validate the tube forming quality. The simulation results revealed that the Type-I process was an appropriate forging process for meeting the quality requirements. For the Type-I process, an underfilling defect was observed at the bottom of the rod section of the tube. The stress concentration in the head section was lower than that in the Type-II process, potentially reducing the probability of crack initiation. Compared to the rod section, the head section may exhibit higher hardness magnitudes due to the greater strain distribution. The experimental results confirmed the feasibility of the Type-I process. The increased hardness in the head section may be primarily attributed to the more intense plastic deformation applied to the material in this section by the Type-I process.
... Ichida [8] investigated the grinding performance of HSS with ultrafine grained and conventional CBN grinding wheels, and the results showed that the radial and contour of the grinding wheels have different degrees of wear. Yuan et al. [9] conducted grinding experiments on W6Mo5Cr4V2 HSS roll material using conventional grinding. During processing, the workpieces were subjected to high grinding temperatures, tremendous grinding forces, burning, and high-temperature oxidation. ...
... Therefore, the relationship between the minimizing-comprehensive objective M and each minimizing objective (Y 2 and Y 3 ) was established through the matrix calculations, which are shown as Eq. (9). Finally, the relationship between M and Y 2 , and Y 3 in this paper is shown as Eq. ...
High-speed steel (HSS) rolls are essential critical components in the steel rolling industry. Unfortunately, the working layer material has poor machinability via conventional grinding process for surface dressing because they have excellent properties. Electrochemical grinding (ECG) is a common machining approach that is used for metal materials. A significant factor for the machining quality of metal materials is the electrolytes, and thus, the selection of a suitable electrolyte for ECG is a primary problem. However, the previous studies have presented very little information on the electrolyte selection for ECG of HSS roll material. This paper proposes a method for investigating the selection of a suitable electrolyte for ECG of HSS roll material using electrochemical testing techniques and uniform design (UD) experiments. Electrochemical behavior, such as electrochemical corrosion and passivation behavior, was assessed to select a suitable electrolyte composition. The results indicate that the electrochemical passivation of composite electrolytes is better than that of single-component electrolytes. From the UD-ECG experiments, an optimal electrolyte content is obtained using a stepwise linear regression model and a multi-objective fuzzy programming approach. The results show that the surface machining quality of the optimal composite electrolyte is better than those of groups with other ratio combinations. Therefore, the method and results used to select a suitable electrolyte obtained using a combination of electrochemical testing techniques and ECG experiments may provide the knowledge for ECG machining, such as that of HSS roll materials and other metal materials.
... Jaworski and Trzepieciński [25] pointed out that increased grinding depth could improve the microhardness of HS3-1-1 steel, and the steel is more propensity to structural modifications during grinding. Yuan et al. [26] studied the microhardness of high-speed Steel W6Mo5Cr4V2 and optimized rolled grinding parameters. ...
High-speed cylindrical grinding (HSCG) is an essential method for advanced manufacturing of difficult-to-machine materials, achieving the perfect combination of high efficiency and high surface integrity. This article aims to investigate the surface layer hardness and microstructure of 18CrNiMo7-6 carburized steel in HSCG. Three CBN grinding wheels are used, and the maximum wheel speed (vs) reaches 120 m/s. Results showed that the hardened layer depth formed by HSCG on the workpiece surface is 75 ~ 160 μm, and the hardening degree is 10 ~ 16%. Wheel feed rate (vfr) significantly impacts the hardened layer more than other grinding parameters. Higher grinding temperature causes the phase transformation from high-carbon martensite to tempered sorbate when the vfr = 0.6 mm/min. The reduction of phase volume leads to residual stress changes from compressive to tensile stress, and the hardness drops sharply. Finally, the formation mechanism of hardness and residual stress is analyzed from the phase transformation perspective, and optimized grinding parameters with better surface quality are proposed.
To improve the high-temperature wear resistance of a substrate, in this study, Fe50Cr40Si10 coating was prepared on AISI 1045 steel by the laser cladding technique and the microstructure was characterized by using an optical microscope (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The results show that the coating with a fine and uniform microstructure has a good metallurgical bond with the AISI 1045 steel substrate. The upper layer of the coating is composed of typical equiaxed grains, and the bottom layer has columnar grains. The XRD pattern shows that the phase compositions are Fe-based solid solution (α phase) with Cr and Si and Fe-Cr intermetallics (α′ phase). The average microhardness of the coating is approximately 530 ± 37.5 HV0.5. The elevated-temperature dry sliding wear resistance of laser cladding Fe50Cr40Si10 coating was carried out on a pin-on-disk mode machine at different temperatures and loads. Under the same wear test conditions, the elevated-temperature wear rates of Fe50Cr40Si10 coating were much lower than those of AISI 1045 steel. When the load was 30 N, it was found that the wear mechanism of Fe50Cr40Si10 coating changed from abrasive wear and adhesive wear to oxidation wear with the increase in temperature. At the wear test temperature of 300 °C, the wear mechanism of the coating changed from oxidation wear to abrasive wear and adhesive wear with the increase in loads.
In the present study, a novel grinding wheel design method is proposed to design a wheel for grinding different small helical grooves on the existing helical rake faces of the tool. The proposed method can be applied to manufacture tools with uneven helical rake face like zigzag-edge twist drills. In the proposed method, the processing of the non-wedge groove is initially converted into a superposition of processing steps of several wedge grooves. Then, based on the simplified non-thickness grinding wheel parametric design and envelop graphic design, the grinding wheel capable of processing small wedge grooves with various specified shapes can be obtained. Moreover, through establishing quantitative evaluation criteria, the determination of design parameters concerning the non-thickness grinding wheel is transmitted into an optimization problem. Finally, helical grooves with trapezoid truncation and wedge truncations are simulated on a virtual five-axis machine tool to verify the effectiveness of the grinding wheel design method.
