Factors affecting the surface quality of metal cutting machine and improvement measures
It is important to understand the connotation of
the surface quality of the parts correctly, analyze the various process factors
that affect the surface quality of the machined surface and improve the surface
quality and improve the performance of the product.
Surface quality of
machining, is refers to the parts after machining processed surface micro
roughness, also called the roughness and the processed surface quality directly
affect the processing of physical, chemical and mechanical properties. The
working performance of the products, reliability, life in a large extent
depending on the surface quality of the main parts. Therefore, correctly
understanding the connotations of the surface quality of the parts, analyzing
the machining process influence machining quality of the surface of various
technical factors, to improve the surface quality, improve product performance
has important significance.
1 factors affecting surface quality of machined
surface
1.1 the influence of machine performance on the surface quality of
machined surface
Effect of wear resistance on surface quality
Between a
just finished the friction pair two contact surfaces, initially in the rough
surface of the peaks of touch, the actual contact area is much smaller than the
theoretical contact area and contact with each other in the a very large unit
stress, the actual contact area to produce plastic deformation, elastic
deformation and peak between shear failure, causing serious wear and
tear.
Effect of fatigue strength on surface quality
Under the alternating
load, surface roughness of Valley site easily lead to stress concentration,
fatigue and grain production. Surface roughness value is bigger, deeper surface
marks, lines at the end of radius more, the anti fatigue ability is worse.
Residual stress on the fatigue strength of parts influence great. Surface
residual tensile force makes the fatigue crack expansion, accelerate fatigue
damage; and surface residual stress can prevent fatigue crack propagation,
delaying fatigue failure.
Influence of corrosion resistance on surface
quality
The corrosion resistance of the parts in a large extent depending on
the surface roughness. Surface roughness value is bigger, valley of the
accumulation of corrosion material more. Corrosion resistance is worse. Surface
layer of residual tensile stress will cause stress corrosion cracking, reduce
the wear resistance of the parts, and the residual compressive stress can
prevent stress corrosion cracking.
1.2 factors affecting surface
roughness
Factors affecting surface roughness of machining
Tool geometry
reflect the tool relative to the workpiece feed movement, on the machined
surface leave the cutting layer residual area, its shape is reflection of the
tool geometry. (2) of the workpiece material properties processing plastic
materials, by the tool of metal extrusion to produce the plastic deformation,
coupled with the tool force cutting chip and workpiece separating the tearing
effect, make the surface rough degree value increase. 3 cutting machining of
brittle materials, cutting speed to have little effect on the roughness; plastic
processing of materials, product crumbs tumor has the effects of
roughness.
Factors affecting surface roughness of grinding
Main factors
affecting the grinding surface roughness: grain wheel, the hardness of the
grinding wheel, wheel dressing, grinding speed, radial grinding, feed rate and
light grinding times, workpiece circular feed speed and the axial feed rate and
cooling lubricating fluid, such as.
1.3 factors affecting the physical and
mechanical properties of the machined surface layer
Cold hardening of the
surface layer
The plastic deformation in the machining process for the
cutting force, make character distortion, distortion, shear slip between grains,
grains are elongated and fibrosis, or even broken, these will cause the surface
layer of metal hardness and strength increased, this phenomenon is known as cold
hardening (or strengthening) main factors. Effects of cold hardening are:
cutting edge radius increases, to enhance the effect of surface metal extrusion,
plastic deformation increased, lead to increased. Chill increase tool flank
wear, flank friction and machined surface intensified, plastic deformation
increases, resulting in chilled increase. The increase of cutting speed, effect
time of the tool and the workpiece is shortened, the plastic deformation
propagation depth decreases, chill depth decreased. The increase of cutting
speed, cutting time of heat in the surface layer on the cut, will make the chill
increases. With feed rate, cutting Stress increase, the plastic deformation of
the metal surface intensified, chill effect strengthened. Workpiece material
plastic is bigger, chilled phenomenon is more serious.
Microstructure change
of surface layer material
When the cutting heat to be machined surface
temperature exceeds the phase transition temperature, metallographic structure
of metal surface will change. Main grinding burn, quenching and annealing burn.
Improve grinding burn has two ways: one is as far as possible to reduce grinding
heat generation; the second is improving cooling condition, try to make the heat
produced with less transmission of the work piece. Correct selection of grinding
wheel, a reasonable choice of cutting parameters improve the cooling
conditions.
Residual stress in the surface layer
Surface residual stresses
are generated: one is cutting in the metal surface layer generated residual
stress, and in the metal layer residual tensile force. The second is cutting,
the cutting area will produce a lot of cutting heat. The third is different
microstructure of surface layer of metal gold phase changes, changes in the
surface of the metal volume must blocked on and connected to the base metal, and
the produce of the residual stress.
2 measures to improve the surface quality
of machined parts
2.1 to establish a scientific and reasonable technological
process is the basis of ensuring the surface quality of the
workpiece.
Workpiece processing method on the basis of the scientific and
reasonable procedure. Only by formulating a scientific and reasonable process
rules, to the workpiece surface quality meet the requirements to provide
scientific and reasonable methods according to, the surface quality of the
workpiece machined meet the requirements become possible. Requirements of
scientific and rational process planning is the process should be short,
positioning accuracy, positioning norm choice as far as possible, the
positioning and design datum coincidence.
2.2 a reasonable choice of cutting
parameters is the key to ensure the quality of processing
Choosing the
reasonable cutting parameters can effectively inhibit the formation of built-up
deposition and reduce the residual area processing theory of height, ensure the
surface quality of the workpiece. The choice of cutting parameters mainly
include the selection of cutting tool angle, cutting speed and cutting depth and
feed speed of choice. Test results show that in processing plastic materials if
choose larger rake angle of the tool can effectively inhibit the product a
built-up formation, which is because of the tool rake angle increases, reducing
the cutting force cutting deformation, cutting tool and the chip contact length
becomes shorter, reducing the base of built-up edge formation.
2.3 a
reasonable choice of cutting fluid is a necessary condition to ensure the
surface quality of the machined workpiece.
Choosing the reasonable cutting
fluid can improve the friction coefficient between the workpiece and the cutting
tool, which can reduce the cutting force and cutting temperature, so as to
reduce the tool wear and tear, so as to guarantee the machining quality of the
workpiece.
2.4 the choice of the final working procedure of the main working
surface is very important.
Workpiece main work surface machining method
selection is very important, because the final step in left on the surface of
the residual stress will directly affect the performance of machine parts. Parts
the main work surface processing method, the specific working conditions of the
main working parts surface and possible failure modes should be taken into
account.
Is closely related to the surface quality of the workpiece and its
performance and the using performance of the workpiece is to ensure the normal
operation of the machine is the premise of the design requirements, so in the
process of machining workpiece, we also from economic benefits and other aspects
to consider, can not only guarantee the machining quality of the workpiece
surface, and avoid increasing the manufacturing cost of the parts, causing
unnecessary losses. Only to understand and grasp the factors affecting the
quality of surface machining to in the production practice, take corresponding
technical measures, reduce parts due to the surface quality defects caused by
the machining quality problem, so as to improve the use of mechanical product
performance, life and reliability.
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