An improved material constitutive model for simulation of high-speed cutting of 6061-T6 aluminum alloy with high accuracy

Xu, Daochun; Feng, Pingfa; Li, Wenbin; Ma, Yuan

doi:10.1007/s00170-015-6888-6

Cited by 17 publications

(5 citation statements)

References 23 publications

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“…Using HSC it is possible to shorten the main cutting time (even by more than 30%), increase the volumetric material removal rate, reduce the cutting force and achieve a better quality of the machined surface. The advantages of high-speed machining also include: limited burr formation, better chip disposal and increased process stability [8][9][10][11][12]. Fig.…”

Section: Introductionmentioning

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: Introductionmentioning

confidence: 99%

High-Performance Milling Techniques of Thin-Walled Elements

Zawada-Michałowska¹

2022

Adv. Sci. Technol. Res. J.

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“…Their application enables milling to be used in new fields, such as the machining of thin-walled components. Recently, there were two ways of developments in milling: high-speed cutting (HSC) and high-performance cutting (HPC) [ 32 , 33 , 34 , 35 , 36 ]. In the machining of thin-walled workpieces, the application of the HSC method seems to be particularly advantageous, as it is characterized by a reduction in the cutting force after exceeding a certain limit value of the cutting speed v c .…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to that of other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.

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“…While surface ion injection, 4,5 surface plating, 6,7 and surface nanocrystal modification 8,9,10,11 can all be used to improve the wear resistance of aluminum alloy, as these processes are too costly and complicated for mass production, cutting has become the most preferred means to manufacture high-strength aluminum alloy parts. 12,13,14,15,16 After parts are cut, their surface morphology is primarily affected by cutting parameters. Lixin et al 17 studied the effects of cutting parameters on the machined surface morphology of 7075-T6 aluminum alloy under dry cutting, and discovered that the percentage of a peak value of surface to the maximum height is influenced by feed and back feed.…”

Section: Introductionmentioning

confidence: 99%

Surface integrity and wear evolution of high strength aluminum alloy after high-speed oblique cutting

Xiao

Wang

Zhang

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part J:

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In this paper, we present an experimental study on the surface frictional wear mechanism of the high-strength aluminum alloy after high-speed milling. We use a surface profilometer and an X-ray stress tester to characterize the milled surface integrity of the material, and UMT-3 friction testing machine to obtain its surface roughness, oxygen content, hardness, and wear morphology during different wear stages. The results show that milling-induced residual tensile stress makes the cut surface more prone to fatigue cracking and consequently abrasive wear in the initial wear stage. The larger the angle between the friction pair movement direction, the greater the chance of adhesive wear and abrasive wear. A complete friction stage pattern can be obtained at a high load (15 N) and a low sliding speed (0.6 mm/s). The friction pair enters a stable wear stage after 20 sliding cycles. Work hardening constitutes the main driver of stable wear.

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An improved material constitutive model for simulation of high-speed cutting of 6061-T6 aluminum alloy with high accuracy

Cited by 17 publications

References 23 publications

High-Performance Milling Techniques of Thin-Walled Elements

High-Performance Milling Techniques of Thin-Walled Elements

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

Surface integrity and wear evolution of high strength aluminum alloy after high-speed oblique cutting

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