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Wang M.,Beijing Institute of Technology | Wang M.,National Key Laboratory for Remanufacture | Wang M.,Tiandi Science And Technology | Xu B.,National Key Laboratory for Remanufacture | And 3 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2013

Fe-based amorphous alloy, a new-type material, was developed as a special-purpose welt overlay for remanufacture. It was deposited on the worn-out part for resuming and upgrading part performance. The microstructure characteristics of the overlay was characterized, including microstructure, phase composition, thermostability, and microhardness. In order to get a comprehensive insight to the machining process of amorphous overlay, this paper presents an experimental investigation into the effect of various machining parameters and tool geometry (Edge) on the surface roughness, tool wear, chip morphology, and surface damage. Comparing larger rake angle of 15°and smaller nose radius of 0.4 mm with 5°and 0.8 mm at the same cutting parameters, we found that larger rake angle of 15°and smaller nose radius of 0.4 mm increased the R a surface roughness parameter. In the tests, crater wear was not observed, and the friction and wear on the minor cutting edge wear were heavy due to the spring back of the machined surface. In brief,abrasion, adhesion, fatigue, and chipping are the main wear mechanism. As the feed rate reduced and the depth of cut increased (from feed rate∈=∈0.06 mm/rev and depth of cut∈=∈0.3 mm to feed rate∈=∈0.09 mm/rev and depth of cut∈=∈0.2 mm), a number of physical changes occurred in the chip including reduced distance between serrations, increased shear band angle, and changed chip morphology from spiral to ribbon shape. The results show that strain and strain rate rises in the chips' inside with the increase in cutting temperature. When the thermal softening exceeded strain hardening, the shear resistance decreased rapidly. Thus, the free surface of the chip presents the nodular and lamella structure. It was noted that specimens generated by larger rake angle of 15°and smaller nose radius of 0.4 mm showed poor surface roughness as well as extensive surface damage. © 2012 Springer-Verlag London. Source


Wang M.,Beijing Institute of Technology | Wang M.,National Key Laboratory for Remanufacture | Wang M.,Tian Di Science and Technology Co. | Xu B.,National Key Laboratory for Remanufacture | And 3 more authors.
International Journal of Advanced Manufacturing Technology | Year: 2012

Fe-based amorphous alloy is a new-type material dedicated to the remanufacture due to its unique property. Fe-based amorphous alloy is deposited on the abrased, fatigued, and fractured surface for resuming and upgrading its performance. In the present research, properties of amorphous alloy overlay, such as the microstructure, the phase content, thermal behavior, and mechanical property were evaluated and its machinability with respect to machining forces was experimentally investigated. Based on the response surface methodology and Box-Behnken design, four-factor (cutting speed, feed, depth of cut, and rake angle) three-level experiments were applied and analysis of variance (ANOVA) was performed. It is found that depth of cut is the dominant cutting parameter that affects the machining force components. Rake angle and interaction of feed rate and depth of cut can provide secondary significance to machining forces. Cutting speed, alone, has insignificant influence on machining force components. Predicting model for machining forces is established. ANOVA indicates that a linear model best fits the radial force and while a quadratic model best describes the axial force and cutting force. The optimal cutting parameters under these experimental conditions are searched. © 2012 Springer-Verlag London Limited. Source

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