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Sustainable manufacturing: re-contouring of laser cladding restored parts by machining method with cutting energy management

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Abstract

Laser cladding has been commonly utilized for restoring high value-added parts. However, the poor surface quality becomes key technological barrier which restricts its widespread applications. In the paper, re-contouring strategies by machining method are explored for minimal energy consumption as well as required surface roughness. Firstly, the effect of structural characteristics of the laser-cladded workpiece on specific cutting energy was explored by means of layer-by-layer turning and orthogonal cutting. Results indicated that the specific cutting energy increased, and the machining chatter/vibration exacerbated with decreasing coating thickness under fixed cutting parameters. The reason can be summarized as a result of the effect of elastoplastic deformation behavior across the interface. Then, the influences of depth of cut and feed on specific cutting energy in finish turning were addressed. Results indicated that the specific cutting energy reduced with increasing depth of cut and feed in the form of power functions. In addition, energy efficiency decreased with an increase in uncut chip thickness and cutting speed. On basis of this work, large feed and low cutting speed with the adoption of wiper inserts were recommended for minimizing energy consumption within surface roughness requirement.

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Abbreviations

Symbols:

Descriptions

a 0 :

Uncut chip thickness in orthogonal cutting (mm)

a c :

Equivalent chip thickness (mm)

a p :

Depth of cut (mm)

E :

Elastic moduli (GPa)

E f :

Friction energy (GN/m2)

E s :

Shear energy (GN/m2)

E u :

Specific cutting energy (GN/m2)

F s :

Shear force (N)

Fx, Fy and Fz :

Cutting force components (N)

f :

Feed (mm/rev)

t c :

Cutting time (s)

V chip :

Material removal volume (m3)

v c :

Cutting speed (m/min)

v s :

Shear velocity (m/min)

w :

Cutting width in orthogonal cutting (mm)

β :

Friction angle at the tool-chip interface (°)

γ :

Tool rake angle (°)

ε :

Strain

η u :

Cutting energy efficiency

μ :

Friction coefficient at the tool-chip interface

σ :

Stress (MPa)

ϕ :

Shear angle (°)

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Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant numbers 51425503, 51675289), Key Technology Research and Development Program of Shandong (Grant number 2018GGX103023), and Shandong Provincial Key Laboratory of Mine Mechanical Engineering (Grant number 2019KLMM209).

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan, 250353, People’s Republic of China

    Peirong Zhang, Jin Du, Tingting Zhou & Guosheng Su

  2. Shandong Province Key Laboratory of Mine Mechanical Engineering, Shandong University of Science and Technology, Qingdao, 266590, People’s Republic of China

    Weimin Huang

  3. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Zhanqiang Liu

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  1. Peirong Zhang
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Correspondence to Peirong Zhang.

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Zhang, P., Du, J., Zhou, T. et al. Sustainable manufacturing: re-contouring of laser cladding restored parts by machining method with cutting energy management. Archiv.Civ.Mech.Eng 20, 42 (2020). https://doi.org/10.1007/s43452-020-00045-x

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  • DOI: https://doi.org/10.1007/s43452-020-00045-x

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