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Enhancing surface integrity by high-speed extrusion machining

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Abstract

High-speed machining (HSM) is an advanced machining technology to form components. However, the poor surface integrity tends to appear due to chip flow instability in HSM. It is found that the surface integrity results from the competition of shear deformation instability between in primary shear zone (PSZ) and in separating shear zone (SSZ). To improve the surface integrity of machined components, the systematic high-speed extrusion machining (HSEM) experiments of magnesium alloy AZ31B with different constraint extrusion factors (CEFs) were carried out. The instability of shear deformation in PSZ is suppressed, and the microwaves on machined surface disappear when CEF is equal to or larger than a certain value. The measurements of the machined surface show that an improvement of surface integrity is achieved if CEF exceeds a certain value. The theoretical model for HSEM was established to elucidate the critical CEF. The underlying physics of surface integrity in HSEM is further revealed. The experimental results verify the validity of the theoretical model.

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Authors and Affiliations

  1. School of Mathematics and Physics, University of Science and Technology Beijing, Beijing, 100083, People’s Republic of China

    Yao Liu & Xinchun Shang

  2. China Electric Power Research Institute, State Grid Corporation of China, Beijing, 100192, People’s Republic of China

    Songlin Cai

  3. State Key Laboratory of Nonlinear Mechanics, Institute of Mechanics, Chinese Academy of Sciences, Beijing, 100190, People’s Republic of China

    Lanhong Dai

Authors
  1. Yao Liu
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  2. Songlin Cai
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  3. Xinchun Shang
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  4. Lanhong Dai
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Corresponding authors

Correspondence to Songlin Cai or Lanhong Dai.

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Liu, Y., Cai, S., Shang, X. et al. Enhancing surface integrity by high-speed extrusion machining. Int J Adv Manuf Technol 89, 2141–2150 (2017). https://doi.org/10.1007/s00170-016-9252-6

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  • DOI: https://doi.org/10.1007/s00170-016-9252-6

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