Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

Czyżycki, Jakub; Twardowski, Paweł; Znojkiewicz, Natalia

doi:10.3390/ma14164771

Cited by 13 publications

(9 citation statements)

References 27 publications

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“…Authors in the work [23] tested the possibility of using a high-speed camera to control deformation during machining. Fixed cutting parameters were adopted and time displacements were tested for a fixed sample point.…”

Section: Introductionmentioning

confidence: 99%

“…High-quality companies use such systems that give the necessary information [29,30]. The term "information system" can be defined as a system of formalized procedures that enable the management of internal and external information, which is used for planning, management, and control purposes [19,[22][23][24][25][26][27][28][29][30][31][32][33][34][35].…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

et al. 2023

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Thin-walled elements are widely used in the aerospace industry, where the aim is to reduce the process time and the weight of the structure while ensuring the sufficient quality of the finished product. Quality is determined by geometric structure parameters and dimensional and shape accuracy. The main problem encountered during the milling of thin-walled elements is the deformation of the product. Despite the various methods available for measuring deformation, more are still being developed. This paper presents selected surface topography parameters and deformation of vertical thin-walled elements during an experiment under controlled cutting conditions for samples from titanium alloy Ti6Al4V. Constant parameters of feed (f), cutting speed (Vc,) and tool diameter (D) were used. Samples were milled using a tool for general-purpose and a tool for high-performance machining, as well as two different machining approaches: with greater involvement of face milling, and cylindrical milling with a constant material removal rate (MRR). For samples with vertical thin walls, the parameters of waviness (Wa, Wz,) and roughness (Ra, Rz) were measured using a contact profilometer in the selected areas on both processed sides. Deformations were determined in selected cross-sections perpendicular and parallel to the bottom of the sample using GOM measurement (GOM—Global Optical Measurement). The experiment showed the possibility of measuring deformations and deflection arrows of thin-walled elements proceeded from titanium alloy using GOM measurement. Differences in selected surface topography parameters and deformations were observed for the machining methods used with an increased cross-section of the cut layer. A sample with a deviation of 0.08 mm from the assumed shape was obtained.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

et al. 2023

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“…It is estimated that aircraft manufacturers incur economic losses amounting to hundreds of millions of dollars (or even more) due to strain in these thin-walled components. To ensure production optimization, cost reduction, and improved aircraft operation safety, research should be conducted on residual stress and its root causes, as well as solutions for reducing this stress [ 11 , 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

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“…The efforts to minimise the weight of the produced parts and the accompanying technological difficulties related to, i.e., the machining of thin-walled elements are significant issues both from the scientific and practical points of views. Various sectors, in particular the aviation industry, currently struggle with the issue of unwanted deformations of thinwalled elements following the completed machining process, and the removal of the force holding a given workpiece [23][24][25]. The deformations may range from several micrometres in the case of small parts to several or even a dozen centimetres in large-sized parts [7].…”

Section: Introductionmentioning

confidence: 99%

Effect of the Geometry of Thin-Walled Aluminium Alloy Elements on Their Deformations after Milling

2022

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The aim of this paper is to analyse the effect of the selected geometric properties of thin-walled structures on post-machining deformations. In the study, EN AW-7075 T651 and EN AW-6082 T651 aluminium alloys were used to prepare specially designed thin-walled sample elements, i.e., elements with walls arranged in a semi-open and closed structure and with a dimension of 165 × 262 × 50.8 mm consisting of bottom and vertical stiffening walls and so-called ribs with a thickness of 1 mm. The measurements of the absolute deformations of the thin-walled bottom were performed with the use of a Vista coordinate-measuring machine by Zeiss with a PH10 head by Renishaw. Based on the obtained results, it was found that absolute deformation values were higher for walls arranged in a semi-open structure. It is related to a lower rigidity of the tested structure resulting from the lack of a stiffening wall, which is the so-called “rib”. Notwithstanding the geometry of the elements, greater absolute deformation values were recorded following conventional cutting methods. The use of high-speed cutting (HSC) provided positive outcomes in terms of minimising the deformation of thin-walled elements. Additionally, it was found that higher absolute deformations were obtained for EN AW-7075 T651 alloy.

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Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

Cited by 13 publications

References 27 publications

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Effect of the Geometry of Thin-Walled Aluminium Alloy Elements on Their Deformations after Milling

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