Cutting Performance And Cutting Force Prediction Research Of Super Alloy With Thermal Sprayed Coatings

Nowadays, the technology of thermal spraying is faster developing in mechanical manufacturing and equipment repair, and it is wildly used in the areas of surface consolidation and protection. By spraying hard coatings, protected coatings, decorative coatings etc. on the surface, the substrate can get the performance of good resistance to wear, corrosion and oxidation, high temperature and chemical stability, high hardness as well as electrical isolation. The sprayed coatings also make it possible to prolong the life of substrate and to satisfy the special demand of design. But due to the technical characteristic of thermal spraying and the disadvantage of spraying technique, it is hard to assure surface quality and size precision, especially in the field of navigation and precise machining process, where there is a strict demand, these results make the machining of super alloy coatings be necessary. The grinding as a traditional method is inefficiency and easy to destroy the surface for the huge machining heat. In this paper, the cutting performance of super alloy with thermal spraying coatings is systematically studied through some turning experiments.Cutting force is the most important factor on the machining process. A cutting force measurement system is developed, including the Kistler piezoelectricity dynamometer, electric charge amplifier, PCL818HD data acquisition card and PC. Based on the system, the turning experiments of FZNCr-60A and BKHA coatings have been made. According to the comparison and analysis of cutting force in using three kinds of blades in the turning experiments, it is found that the better effect, which the cutting force is less and the coatings is not easy to break off, can be got by using the blade with bigger rake angle (18°) to turn the relative coating materials. On the basis of orthogonal turning experiments, the cutting force under the different cutting parameters has been measured, the changing rule of cutting force has been analyzed, and the empirical formula of cutting force has been presented. By summarizing the effect of cutting parameters and other factors, it will provide useful reference for turning these kinds of super alloy with thermal sprayed coatings in production.The empirical formula and artificial neural network are used to predict the cutting force of super alloy coatings in this paper, the precision of prediction is compared and analyzed, it is found that neural network is more precise. By deducing the globally convergent adaptive quick back propagation (GCAQBP) and evolving the rule of network right in the grads arithmetic, the character of terminal pulling point is used, the study rate plus λ can adjust...