A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys

Zawada-Michałowska, Magdalena; Pieśko, Paweł; Jóźwik, Jerzy; Legutko, Stanisław; Kukiełka, L.

doi:10.3390/ma14237242

Cited by 10 publications

(7 citation statements)

References 35 publications

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“…The obtained lower wall deformation after High Speed Cutting resulted from lower value of cutting force in comparison to HPC and convent ional machining. Such considerations were presented in [47].…”

Section: Resultsmentioning

confidence: 99%

High-Performance Milling Techniques of Thin-Walled Elements

Zawada-Michałowska¹

2022

Adv. Sci. Technol. Res. J.

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The paper presents an overview of high-performance milling techniques of thin-walled elements. Currently, the tendency to simplify semi-fi nished products is used in aviation. In that case even 95% of semi-fi nished product mass is converted into chips, hence the increasing interest in such techniques as: High Performance Cutting (HPC) and High Speed Cutting (HSC). The aim of the paper was to research high-performance milling techniques of thin-walled elements in reference to conventional machining. The material was the EN AW-7075 T651 aluminium alloy. A thinwalled pocket structure was designed and manufactured. The aspects related to geometric accuracy, surface quality and cutting time were analysed. On the basis of the obtained results, it was found that in case of geometric accuracy associated with the wall deformation, the greatest deformation was obtained after HPC, while the smallest one after HSC. The diff erence was over 400% (comparing HPC to HSC). A similar relationship was also received for the quality of the machined surface. Analysing the cutting time, the best result was achieved after HPC in reference to HSC and conventional machining. Taking into account all analysed variables, prime solution was a combination of HPC and HSC. Thanks to the use of HSC as a fi nishing, it is possible to receive high geometric accuracy and quality of the machined surface, while the application of HPC for roughing allows to shorten the cutting time, translating into an increase in the effi ciency of the milling process. Conventional machining is slightly less advantageous in terms of geometric accuracy and surface quality and it could possibly be used alternatively with High Speed Cutting, but its weakness is signifi cantly lower effi ciency compared to high-performance machining.

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Section: Resultsmentioning

confidence: 99%

High-Performance Milling Techniques of Thin-Walled Elements

Zawada-Michałowska¹

2022

Adv. Sci. Technol. Res. J.

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“…Other studies have also shown that higher geometric accuracy of the manufactured elements is related to an increase in cutting speed. High cutting speeds are recommended to minimize distortion of thin-walled components [ 25 ]. The third tested parameter, the depth of cut, did not have a significant effect on the deformation and surface roughness of produced parts [ 2 ].…”

Section: Introductionmentioning

confidence: 99%

“…The research on machining thin-walled structures sometimes provides contradictory results, because there are also studies showing that the thickness of an aluminum alloy element does not significantly affect the 2D and 3D surface roughness parameters [ 3 ]. Due to the accuracy of workmanship and deformation of thin-walled elements made of aluminum alloys, it is recommended to use carbide tools or tools with PCD blades [ 25 ].…”

Section: Introductionmentioning

confidence: 99%

“…In this study, the same technological parameters as found in milling are used to determine the effect of these parameters on cutting forces, surface roughness and accuracy resulting from gradual milling of thin-walled structures. The parameters were selected based on the literature review [ 2 , 25 , 28 , 35 , 46 , 50 , 53 , 54 ]; thus, their choice is a compromise for all analyzed materials. These parameters are optimal for milling polymer composites and aluminum alloys and maximum for milling titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

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Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Ciecieląg

Zaleski

2022

Materials

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The machining of thin-walled elements used in the aviation industry causes may problems, which create a need for studying ways in which undesirable phenomena can be prevented. This paper presents the results of a study investigating face milling thin-walled elements made of titanium alloy, aluminum alloy and polymer composite. These materials were milled with folding double-edge cutters with diamond inserts. The results of maximum vertical forces and surface roughness obtained after machining elements of different thicknesses and unsupported element lengths are presented. The results of deformation of milled elements are also presented. The results are then analyzed by ANOVA. It is shown that the maximum vertical forces decrease (in range 42–60%) while the ratio of vertical force amplitude to its average value increases (in range 55–65%) with decreasing element thickness and increasing unsupported element length. It is also demonstrated that surface roughness deteriorates (in range 100% for aluminum, 30% titanium alloy, 15% for CFRP) with small element thicknesses and long unsupported element lengths. Long unsupported element lengths also negatively (increasing deformation several times) affect the accuracy of machined elements.

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“…Low forces that occur during brushing processing allow the application to thin-walled parts where low stiffness causes problems in the machining [ 26 , 27 ]. The use of appropriate machining strategies reduces the risk of deformation of thin-wall workpieces.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Effectiveness of Removing Surface Defects by Brushing

et al. 2022

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The paper presents the results of a study on the effectiveness of removing surface defects by brushing. Damage to machine components usually begins on their surface or in the surface layer area. This determines the development of methods, conditions, and process parameters that will positively affect the stereometric and physical properties of the surface layer. Experiments were conducted in which surface defects were generated on a specially designed test stand. By controlling the load and speed of the defect generator it was possible to affect the geometry, depth, and width of the surface defect. A FEM simulation of the brushing treatment was carried out in order to determine the effect of fibers passing through a surface defect in the form of a groove with a small depth and width. It was shown that for certain conditions of brushing treatment, surface defects could be removed effectively. Moreover, the microhardness of the surface layer after the brushing process was analyzed. Changes in microhardness due to brushing reached up to 50 μm for EN AW-2024 aluminum alloy and up to 150 μm for AZ91HP magnesium alloy. The results demonstrated that brushing was an effective method for strengthening the surface layer and that the value of strengthening in the area of defects depended on the effectiveness of their removal.

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A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys

Cited by 10 publications

References 35 publications

High-Performance Milling Techniques of Thin-Walled Elements

High-Performance Milling Techniques of Thin-Walled Elements

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Analysis of the Effectiveness of Removing Surface Defects by Brushing

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