The New Electric Hot Turning Principle And Experimental Verification

Along with the rapid development of modern industrial production, a lot of difficult-to-cut material which has high strength and high hardness or has high temperature resistance has been introduced in many departments such as weapon manufacture, aerospace industry and other machinery industry, in the process of machining there are problems such as bigger cutting force, lower material removal rate, higher material temperature increase,incresed surface hardening, it’s very hard to guarantee the precision and surface quality and serious tool wear, some material even can’t be machined. It’s very hard to satisfy the requirements of modern industrial production by using conventional machining means and conventional machining tool material to machining the difficult-to-cut workpiece material.Hot machining is an effective method for cutting difficult-to-cut material. This article has presented a new electric heating assistted turning method and its heating model, this paper will study this new method’s feasibility and analysis its effects. A dc large current with low voltage is applied to the circuit which is made up of the auxiliary electrode and workpiece. When the large dc current with low voltage flow through the contact resistances which generated by the point contact of auxiliary electrodes and the workpiece a lot of heat generates because of the increase of the current density,the heat makes the temperature of the workpiece rise so the workpiece material hardness decreases.So as to achieve the purpose of improve the cutting efficiency and the tool life. The experimental platform of electric heating assisted turning has been founded in this paper.The experimental platform has an electric heating system and a turning manufacturing process vibration signal collection and processing system that based on virtual instrument. The hardness of the workpieces at high temperatures has been test too, by analysis and processing the collected vibration signals then optimizing the cutting parameters and the electric heat parameters.This method has been proved feasible along with the turning experiments of T10A hardened tool steel (HRC57) and GH2132superalloy, it also has high heating efficiency, simple construction and low cost.By collecting and processing the vibration signal of the comparison experiments with wavelet method and wavelet packet method, it turns out that the vibration amplitude of electric heating assistted turning is5to10times low than the common lubrication turning of TlOA hardened tool steel, on the other hand the turning experiment of GH2132superalloy shows that the cutting tool life improved obviously because of the decrease of the cutting tool burden.Finally it turns out that this new method is reliable and effective, compared to the common lubrication turning it’s better.