The Process Optimization Analysis of CBN Abrasive Cu-Sn-Ti Coating Fabrication via the Ultrasonic-Vibration-Assisted Laser Cladding Method
Abstract
:1. Introduction
2. Fabrication Method and Experiments
2.1. Experimental Equipment
2.2. Fabrication Materials
2.3. Quality Evaluation Parameter
2.3.1. Shape Factor
2.3.2. Dilution Rate
3. Effects of Process Parameters on the Performance of the Printing Layer
3.1. Laser Power
3.2. Sweep Speed
3.3. Powder Feeding Speed
3.4. Ultrasonic Power
4. Process Optimization and Analysis
4.1. Orthogonal Experiment Design and Range Analysis
4.2. Three-Factor Analysis of Variance
5. Surface Morphology Is Affected by Ultrasonic Vibration
6. Preparation of Structured CBN Grinding Wheel
7. Conclusions
- (1)
- The effects of laser power, sweep speed, powder feeding speed, and ultrasonic power on the shape coefficient and dilution rate of the printing layer were analyzed through single-factor experiments. With the gradual increase in laser power, the melt width B and the melt height H increased. As the sweep speed gradually increased, the melt width B and the melt height H decreased. With the increase in the powder feeding speed, the melt width B was reduced and the melt height H increased, while the melt depth h remained basically unchanged. With the increase in ultrasonic power, the width B and height H did not change significantly, and basically maintained stability, while the penetration depth increased slightly.
- (2)
- The optimal range of influencing factors such as laser power, sweep speed, powder feeding speed, and ultrasonic power was determined. The level values for laser power were 220 W, 235 W, and 250 W; the level values for sweep speed were 5 mm/s, 6 mm/s, and 7 mm/s; and the level values for powder feeding speed were 1.7 r/min, 1.8 r/min, and 1.9 r/min. The ultrasonic power level values were 5%, 10%, and 15%.
- (3)
- Range analysis and variance analysis of the experimental results were carried out through orthogonal experiments. The most significant influence on the shape factor γ was the sweep speed, followed by powder feeding speed and laser power. The most significant influence on the height of the printing layer H was laser power and sweep speed. The corresponding optimal parameters were a laser power of 235 W, a sweep speed of 6 mm/s, a powder feeding speed of 1.8 r/min, and an ultrasonic power percentage of 15%. Thus, process parameter optimization was realized.
- (4)
- By comparing the two kinds of grinding wheel printing layers prepared with and without ultrasonic vibration, it was found that the ultrasonic effects can provide the printing layer with better surface morphology constraints. The height of each printing layer was more consistent and the CBN distribution inside the melt pool was uniform. In the case of applying ultrasonic vibration, the difference between the highest point and the lowest point of the exposed height of the CBN particles was small at about 484μm, while the size of the interval without ultrasonic vibration was 1075μm. It is proven that ultrasonic vibration can stabilize the protrusion height of CBN abrasive particles in a range. The sticky powder phenomenon on the surface of the printing layer and the grinding wheel was also improved.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Experimental Instrument | Model |
---|---|
Robotic arm | KUKA ZH30/60 Ⅲ |
Shielding gas | Ar |
Laser head | Raycham RC52 |
Powder-feeding system | RC-PGF-1 |
Laser generator | IPG YLR-500 |
Ultrasonic system | 2000 bdc |
Element | wt% |
---|---|
Cu | Bal. |
Sn | 18.93 |
Ti | 10.37 |
No. | Pl (W) | vs (mm/s) | vr (r/min) | Ps (%) | B (mm) | H (mm) | h (mm) | γ | η |
---|---|---|---|---|---|---|---|---|---|
1 | 200 | 6 | 1.8 | 10 | 0.749 | 0.263 | 0.016 | 2.85 | 5.6 |
2 | 235 | 6 | 1.8 | 10 | 0.873 | 0.303 | 0.018 | 2.88 | 5.6 |
3 | 280 | 6 | 1.8 | 10 | 0.960 | 0.348 | 0.021 | 2.76 | 5.7 |
4 | 315 | 6 | 1.8 | 10 | 1.052 | 0.364 | 0.022 | 2.89 | 5.7 |
5 | 350 | 6 | 1.8 | 10 | 1.278 | 0.415 | 0.026 | 3.08 | 5.8 |
No. | Pl (W) | vs (mm/s) | vr (r/min) | Ps (%) | B (mm) | H (mm) | h (mm) | γ | η |
---|---|---|---|---|---|---|---|---|---|
1 | 235 | 3 | 1.8 | 10 | 1.033 | 0.564 | 0.035 | 1.83 | 5.8 |
2 | 235 | 4 | 1.8 | 10 | 0.971 | 0.460 | 0.028 | 2.11 | 5.7 |
3 | 235 | 5 | 1.8 | 10 | 0.953 | 0.422 | 0.025 | 2.26 | 5.5 |
4 | 235 | 6 | 1.8 | 10 | 0.873 | 0.303 | 0.018 | 2.88 | 5.6 |
5 | 235 | 7 | 1.8 | 10 | 0.838 | 0.290 | 0.016 | 2.89 | 5.2 |
No. | Pl (W) | vs (mm/s) | vr (r/min) | Ps (%) | B (mm) | H (mm) | h (mm) | γ | η |
---|---|---|---|---|---|---|---|---|---|
1 | 235 | 6 | 1.2 | 10 | 0.908 | 0.283 | 0.016 | 3.21 | 5.3 |
2 | 235 | 6 | 1.4 | 10 | 0.911 | 0.298 | 0.017 | 3.06 | 5.4 |
3 | 235 | 6 | 1.6 | 10 | 0.905 | 0.315 | 0.018 | 2.87 | 5.4 |
4 | 235 | 6 | 1.8 | 10 | 0.873 | 0.303 | 0.018 | 2.88 | 5.6 |
5 | 235 | 6 | 2.0 | 10 | 0.871 | 0.310 | 0.017 | 2.81 | 5.4 |
No. | Pl (W) | vs (mm/s) | vr (r/min) | Ps (%) | B (mm) | H (mm) | h (mm) | γ | η |
---|---|---|---|---|---|---|---|---|---|
1 | 235 | 6 | 1.8 | 0 | 0.838 | 0.312 | 0.015 | 2.77 | 4.5 |
2 | 235 | 6 | 1.8 | 5 | 0.861 | 0.304 | 0.017 | 2.83 | 5.5 |
3 | 235 | 6 | 1.8 | 10 | 0.873 | 0.303 | 0.018 | 2.88 | 5.6 |
4 | 235 | 6 | 1.8 | 15 | 0.871 | 0.298 | 0.018 | 2.92 | 5.7 |
Level | A Laser Power Pl (W) | B Sweep Speed vs (mm/s) | C Powder Feeding Speed vr (r/min) | D Ultrasonic Power Percentage Ps (%) |
---|---|---|---|---|
1 | 220 | 5 | 1.7 | 5 |
2 | 235 | 6 | 1.8 | 10 |
3 | 250 | 7 | 1.9 | 15 |
No. | A | B | C | D | B (mm) | H (mm) | γ |
---|---|---|---|---|---|---|---|
1 | 220 | 5 | 1.7 | 5 | 0.615 | 0.501 | 1.23 |
2 | 220 | 6 | 1.9 | 10 | 0.713 | 0.426 | 1.67 |
3 | 220 | 7 | 1.8 | 15 | 0.590 | 0.225 | 2.62 |
4 | 235 | 5 | 1.9 | 15 | 0.977 | 0.592 | 1.64 |
5 | 235 | 6 | 1.8 | 5 | 1.410 | 0.543 | 2.60 |
6 | 235 | 7 | 1.7 | 10 | 0.891 | 0.403 | 2.21 |
7 | 250 | 5 | 1.8 | 10 | 0.928 | 0.481 | 1.93 |
8 | 250 | 6 | 1.7 | 15 | 0.882 | 0.410 | 2.15 |
9 | 250 | 7 | 1.9 | 5 | 0.908 | 0.435 | 2.09 |
Item | Level | A | B | C | D |
---|---|---|---|---|---|
K | 1.7 | - | - | 5.59 | - |
1.8 | - | - | 7.15 | - | |
1.9 | - | - | 5.4 | - | |
5 | - | 4.8 | - | 5.92 | |
6 | - | 6.42 | - | - | |
7 | - | 6.92 | - | - | |
10 | - | - | - | 5.81 | |
15 | - | - | - | 6.41 | |
220 | 5.52 | - | - | - | |
235 | 6.45 | - | - | - | |
250 | 6.17 | - | - | - | |
K avg | 1.7 | - | - | 1.86 | - |
1.8 | - | - | 2.38 | - | |
1.9 | - | - | 1.8 | - | |
5 | - | 1.6 | - | 1.97 | |
6 | - | 2.14 | - | - | |
7 | - | 2.31 | - | - | |
10 | - | - | - | 1.94 | |
15 | - | - | - | 2.14 | |
220 | 1.84 | - | - | - | |
235 | 2.15 | - | - | - | |
250 | 2.06 | - | - | - | |
Optimum level | 235 | 7 | 1.8 | 15 | |
R | 0.31 | 0.71 | 0.58 | 0.2 | |
Level quantity | 3 | 3 | 3 | 3 | |
Number of repetitions per level r | 3 | 3 | 3 | 3 |
Item | Level | A | B | C | D |
---|---|---|---|---|---|
K | 0.05 | - | - | - | 2.93 |
0.1 | - | - | - | 2.53 | |
0.15 | - | - | - | 2.45 | |
1.7 | - | - | 2.39 | - | |
1.8 | - | - | 2.93 | - | |
1.9 | - | - | 2.6 | - | |
5 | - | 2.52 | - | - | |
6 | - | 3 | - | - | |
7 | - | 2.39 | - | - | |
220 | 1.92 | - | - | - | |
235 | 3.28 | - | - | - | |
250 | 2.72 | - | - | - | |
K avg | 0.05 | - | - | - | 0.98 |
0.1 | - | - | - | 0.84 | |
0.15 | - | - | - | 0.82 | |
1.7 | - | - | 0.8 | - | |
1.8 | - | - | 0.98 | - | |
1.9 | - | - | 0.87 | - | |
5 | - | 0.84 | - | - | |
6 | - | 1 | - | - | |
7 | - | 0.8 | - | - | |
220 | 0.64 | - | - | - | |
235 | 1.09 | - | - | - | |
250 | 0.91 | - | - | - | |
Optimum level | 235 | 6 | 1.8 | 0.05 | |
R | 0.45 | 0.21 | 0.18 | 0.16 | |
Level quantity | 3 | 3 | 3 | 3 | |
Number of repetitions per level r | 3 | 3 | 3 | 3 |
Item | Level | A | B | C | D |
---|---|---|---|---|---|
K | 0.05 | - | - | - | 1.48 |
0.1 | - | - | - | 1.31 | |
0.15 | - | - | - | 1.23 | |
1.7 | - | - | 1.31 | - | |
1.8 | - | - | 1.25 | - | |
1.9 | - | - | 1.45 | - | |
5 | - | 1.57 | - | - | |
6 | - | 1.38 | - | - | |
7 | - | 1.06 | - | - | |
220 | 1.15 | - | - | - | |
235 | 1.54 | - | - | - | |
250 | 1.33 | - | - | - | |
K avg | 0.05 | - | - | - | 0.49 |
0.1 | - | - | - | 0.44 | |
0.15 | - | - | - | 0.41 | |
1.7 | - | - | 0.44 | - | |
1.8 | - | - | 0.42 | - | |
1.9 | - | - | 0.48 | - | |
5 | - | 0.52 | - | - | |
6 | - | 0.46 | - | - | |
7 | - | 0.35 | - | - | |
220 | 0.38 | - | - | - | |
235 | 0.51 | - | - | - | |
250 | 0.44 | - | - | - | |
Optimum level | 235 | 5 | 1.9 | 0.05 | |
R | 0.13 | 0.17 | 0.07 | 0.08 | |
Level quantity | 3 | 3 | 3 | 3 | |
Number of repetitions per level r | 3 | 3 | 3 | 3 |
Difference Source | Sum of Squares | df | Mean Square | F | p |
---|---|---|---|---|---|
Intercept | 36.562 | 1 | 36.562 | 481.856 | 0.002 ** |
B | 0.819 | 2 | 0.409 | 5.395 | 0.156 |
C | 0.615 | 2 | 0.307 | 4.051 | 0.198 |
D | 0.068 | 2 | 0.034 | 0.448 | 0.69 |
Residual | 0.152 | 2 | 0.076 |
Difference Source | Sum of Squares | df | Mean Square | F | p |
---|---|---|---|---|---|
Intercept | 6.959 | 1 | 6.959 | 44.686 | 0.022 * |
B | 0.07 | 2 | 0.035 | 0.225 | 0.816 |
C | 0.049 | 2 | 0.025 | 0.159 | 0.863 |
D | 0.045 | 2 | 0.022 | 0.143 | 0.875 |
Residual | 0.311 | 2 | 0.156 |
Difference Source | Sum of Squares | df | Mean Square | F | p |
---|---|---|---|---|---|
Intercept | 1.792 | 1 | 1.792 | 143.864 | 0.007 ** |
B | 0.044 | 2 | 0.022 | 1.78 | 0.36 |
C | 0.007 | 2 | 0.004 | 0.291 | 0.775 |
D | 0.011 | 2 | 0.005 | 0.441 | 0.694 |
Residual | 0.025 | 2 | 0.012 |
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Li, J.; Ma, M.; Yu, T.; Li, M.; Zhao, J. The Process Optimization Analysis of CBN Abrasive Cu-Sn-Ti Coating Fabrication via the Ultrasonic-Vibration-Assisted Laser Cladding Method. Appl. Sci. 2024, 14, 7790. https://doi.org/10.3390/app14177790
Li J, Ma M, Yu T, Li M, Zhao J. The Process Optimization Analysis of CBN Abrasive Cu-Sn-Ti Coating Fabrication via the Ultrasonic-Vibration-Assisted Laser Cladding Method. Applied Sciences. 2024; 14(17):7790. https://doi.org/10.3390/app14177790
Chicago/Turabian StyleLi, Juncai, Mingze Ma, Tianbiao Yu, Ming Li, and Ji Zhao. 2024. "The Process Optimization Analysis of CBN Abrasive Cu-Sn-Ti Coating Fabrication via the Ultrasonic-Vibration-Assisted Laser Cladding Method" Applied Sciences 14, no. 17: 7790. https://doi.org/10.3390/app14177790