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How to process materials with severe deformation at specific temperatures?

To address the issue of severe deformation of a certain material at a specific temperature, multiple aspects need to be considered during processing to control and reduce deformation. Here are some specific suggestions:

1.  Material selection and pretreatment

1.1. Choose materials with high thermal conductivity:

Prioritize the use of materials with high thermal conductivity, such as aluminum alloys or copper alloys, which can effectively dissipate heat and reduce the risk of thermal deformation.

If it is not possible to replace the material, it may be considered to apply a high thermal conductivity coating on the surface of the workpiece, such as an aluminum nitride (AlN) coating, to enhance heat dissipation capability.

1.2. Homogenization treatment:

Perform heat treatment on the workpiece, such as quenching or annealing, to reduce the unevenness of internal hardness, thereby reducing the accumulation of heat and deformation caused by hardness changes during the cutting process.

2、 Optimize processing technology parameters

Reduce cutting speed:

By reducing the cutting speed, the heat generated during the cutting process can be minimized, thereby reducing the temperature rise and thermal deformation risk of the workpiece. Adjust feed rate:

Reducing the feed rate helps to lower cutting force and cutting temperature, reducing the risk of tool wear and workpiece surface quality degradation. Using multiple shallow cuts:

Reducing the cutting depth and using multiple shallow cuts to complete the machining can reduce the heat input of each cut, thereby reducing the risk of thermal deformation.

3、 Using an efficient coolant system

Configure an efficient coolant system to ensure that the coolant can evenly and fully cover the surface of the workpiece.

Choose a coolant with high thermal conductivity and good cooling effect, such as water-based or oil-based coolant, and regularly check and maintain its flow rate and spray angle to ensure that the coolant can quickly remove the heat generated during the cutting process.

4、 Optimize tool selection and usage

4.1. Choose high thermal conductivity tool materials:

Choose cutting tools made of high thermal conductivity materials such as hard alloys or ceramics to reduce the accumulation of tool temperature.

4.2. Use coating technology:

Coating the surface of the tool with a high thermal conductivity coating, such as titanium nitride (TiN) or aluminum nitride (AlN) coating, to enhance the heat dissipation performance of the tool.

4.3. Optimize tool geometry:

Reduce heat accumulation on each cutting edge by increasing the number of cutting edges or adopting sharper blade designs.

5、 Control processing temperature and environment

5.1. Strictly control the processing temperature:

Use temperature control equipment or maintain stable ambient temperature to prevent thermal expansion of the workpiece due to fluctuations in ambient temperature.

5.2. Preheating of workpieces:

Before processing, uniformly heat the workpiece to a temperature close to the expected temperature during processing, thereby reducing thermal expansion caused by temperature differences.

6、 Other auxiliary measures

6.1. Choose the appropriate fixing device:

Use appropriate fixing devices and fixtures, such as clamping devices or support devices, during the machining process to control the stress release and deformation of the workpiece.

6.2. Conduct tool testing:

Conduct tool testing before formal processing, select the most suitable tool material and coating combination to ensure that the tool can work stably under established processing conditions.