پارسا حسين زاده

A generator is one of the most essential pieces of equipment for electrical energy production an‎d is generally composed of two main parts: the stator an‎d the rotor. In addition to carrying the excitation windings, the rotor is responsible for providing a suitable path for magnetic flux an‎d transmitting mechanical torque. This component is commonly manufactured from 26NiCrMoV14-5 alloy steel, which is widely used in power plant rotor manufacturing due to its high mechanical strength, suitable machinability, an‎d desirable magnetic properties. Slots are created on the rotor surface to accommodate the copper conductors of the excitation system. The design an‎d dimensional accuracy of these slots play a decisive role in the mechanical strength, electromagnetic performance, an‎d operational reliability of the generator. These slots are mainly produced through the slot machining process, which is considered one of the most costly stages in rotor manufacturing.Previous studies have shown that, in many machining processes, a significant portion of tool wear occurs during the transient time region within the first few seconds of cutting, an‎d optimizing cutting parameters during this period can lead to an increase in the ultimate tool life. Accordingly, it was expected that, in the slot machining process of this rotor material, the initial cutting conditions would also have a direct effect on tool wear behavior an‎d the overall machining performance.In this research, in order to investigate this hypothesis, the slot machining operation of 26NiCrMoV14-5 steel rotor was carried out using PVD-coated carbide cutting tools under different levels of cutting speed an‎d feed rate. After each test, the flank wear of the tool was measured, an‎d for a more detailed analysis of wear mechanisms, the samples were examined using an optical microscope an‎d a scanning electron microscope. The results showed that variations in cutting speed an‎d feed rate during the transient region had a direct influence on the initial wear rate, wear progression trend, an‎d ultimate tool life. The best tool performance was achieved at a feed rate of 0.125 mm/rev an‎d a cutting speed of 60 m/min, which resulted in an 18% increase in tool life under the optimum cutting speed condition an‎d approximately 27% under the optimum feed rate condition, compared with the reference condition. The findings of this study indicate that simultaneous optimization of cutting parameters in the transient time region can lead to reduced tool wear, increased useful tool life, an‎d improved productivity in the rotor slot machining process.

سايش پهلوي ابزار , سايش اوليه , ماشينكاري , 26nicrmov 14 5

tool flank wear , initial wear , machining , 26 nicrmov 14 5

parsa hosseinzadeh

seyed ali niknam