Mechanism and machinability in novel electroplastic-assisted grinding ductile iron

Jia-Hao Liu; Dong-Zhou Jia; Chang-He Li; Yan-Bin Zhang; Ying Fu; Zhen-Lin Lv; Shuo Feng

doi:10.1007/s40436-024-00533-w

Advances in Manufacturing ›› : 1 -19. DOI: 10.1007/s40436-024-00533-w

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Mechanism and machinability in novel electroplastic-assisted grinding ductile iron

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¹ College of Mechanical Engineering and Automation, Liaoning University of Technology, 121001, Jinzhou, Liaoning, People’s Republic of China

² School of Mechanical & Automotive Engineering, Qingdao University of Technology, 266520, Qingdao, Shandong, People’s Republic of China

³ Songshan Lake Material Laboratory, 523808, Dongguan, Guangdong, People’s Republic of China

⁴ School of Materials Science and Engineering, Xi’an University of Technology, 710048, Xi’an, People’s Republic of China

^b jia_dongzhou@163.com

Jia-Hao Liu is a master student at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Dong-Zhou Jia is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Chang-He Li is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Yan-Bin Zhang is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Ying Fu is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Zhen-Lin Lv is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

Shuo Feng is a lecturer at the School of Mechanical Engineering and Automation, Liaoning University of Technology, Jinzhou, China. He received his Ph.D. degree from Qingdao University of Technology, China, in 2021. His current research interests focus on precision and special machining technology, multi-energy field composite machining technology.

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Abstract

Owing to the hard brittle phase organization in their matrixes, brittle materials are prone to the formation of pits and cracks on machined surfaces under extreme grinding conditions, which severely affect the overall performance and service behavior of machined parts. Based on the electroplastic effect of pulsed currents during material deformation, this study investigates electroplastic-assisted grinding with different electrical parameters (current, frequency, and duty cycle). The results demonstrate that compared to conventional grinding, the pulsed current can significantly decrease the surface roughness (S _a) of the workpiece and reduce surface pits and crack defects. The higher the pulsed current, the more pronounced the improvement in the surface quality of the workpiece. Compared to traditional grinding, when the pulsed current is 1 000 A, S _a decreases by 46.4%, and surface pit and crack defects are eliminated. Under the same pulse-current amplitude and frequency conditions, the surface quality continues to improve as the duty cycle increases. When the duty cycle is 75%, S _a reaches a minimum of 0.749 μm. However, the surface quality is insensitive to the pulsed-current frequency. By investigating the influence of pulsed electrical parameters on the surface quality of brittle material under grinding conditions, this study provides a theoretical basis and technical support for improving the machining quality of hard, brittle materials.

Keywords

Electroplasticity / Grinding machining / Brittle material / Pulse parameters / Surface quality

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Jia-Hao Liu, Dong-Zhou Jia, Chang-He Li, Yan-Bin Zhang, Ying Fu, Zhen-Lin Lv, Shuo Feng. Mechanism and machinability in novel electroplastic-assisted grinding ductile iron. Advances in Manufacturing 1-19 DOI:10.1007/s40436-024-00533-w

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