Assessment of the Accuracy of High-Speed Machining of Thin-Walled EN AW-2024 Aluminium Alloy Elements Using Carbide Milling Cutter and with PCD Blades

Kuczmaszewski, Józef; Łogin, Waldemar; Pieśko, Paweł; Zawada-Michałowska, Magdalena

doi:10.1007/978-3-319-68619-6_64

Cited by 9 publications

(12 citation statements)

References 6 publications

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“…Furthermore, especially with respect to layers subtracted at a small radial depth of cut, the temperature in the area of cut is reportedly smaller [6]. PCD-cutter tools have been widely reported to produce better quality of surface finish, generate lower cutting force values and prevent tool overheating by decreasing friction at tool–workpiece interface [10]; consequently, the temperatures in the area of cut are significantly lower [11,12,13]. The cutting tool was the subject of analysis in the study by Zagórski et al [14,15], which investigated the AZ91HP magnesium alloy machining with “serrated”, i.e., “wavy-edged”, cutting tools.…”

Section: Introduction—state-of-the-artmentioning

confidence: 99%

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys

et al. 2019

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This paper set out to investigate the effect of cutting speed vc and trochoidal step str modification on selected machinability parameters (the cutting force components and vibration). In addition, for a more detailed analysis, selected surface roughness parameters were investigated. The research was carried out for two grades of magnesium alloys—AZ91D and AZ31—and aimed to determine stable machining parameters and to investigate the dynamics of the milling process, i.e., the resulting change in the cutting force components and in vibration. The tests were performed for the specified range of cutting parameters: vc = 400–1200 m/min and str = 5–30%. The results demonstrate a significant effect of cutting data modification on the parameter under scrutiny—the increase in vc resulted in the reduction of the cutting force components and the displacement and level of vibration recorded in tests. Selected cutting parameters were modelled by means of Statistica Artificial Neural Networks (Radial Basis Function and Multilayered Perceptron), which, furthermore, confirmed the suitability of neural networks as a tool for prediction of the cutting force and vibration in milling of magnesium alloys.

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Section: Introduction—state-of-the-artmentioning

confidence: 99%

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys

et al. 2019

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“…In industrial practice, among others, interoperational heat treatment, e.g., relief annealing is used to remove residual stresses. Due to economic reasons, such operations are being eliminated, as they generate additional costs and increase the production time significantly [ 4 , 9 , 14 , 15 , 16 , 17 , 18 ].…”

Section: Introductionmentioning

confidence: 99%

“…Additionally, common problems related to thin-walled element machining include [ 15 , 42 , 43 , 44 ]: maintaining good surface quality; difficulties in ensuring required dimensional and shape accuracy; the presence of self-excited vibrations (“chatter”) disturbing the machining process stability. …”

Section: Introductionmentioning

confidence: 99%

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Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

et al. 2020

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The paper examines the impact of selected machining techniques and the semi-finished product technological history on deformations of thin-walled elements made of EN AW-2024 T351 aluminium alloy after milling. The following techniques have been implemented: High Performance Cutting, High Speed Cutting, conventional finishing (CF) and combinations of these techniques. As for the semi-finished product technological history, the rolling direction has been analysed. It has been assumed that it can be relevant in relation to the cutting tool feed direction and, in consequence, exert considerable impact on the stress, as well as deformation following machining. The interest in this issue proceeds from significant challenges faced by the industry, particularly in the aerospace sector. The analysis of results obtained has shown that milling in the direction perpendicular to the rolling direction results in larger deformations than milling in the parallel direction. Additionally, it has been revealed that applying a correctly selected machining technique makes it possible to minimise post-machining deformations of thin-walled elements.

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“…The cutting forces and their change during machining are among the key machinability indices, which is why we have already attempted to approach them in our previous scientific works [13]. Analysis of amplitudes in cutting provides the source of data regarding the generation of vibrations during machining, which is essential with respect to thin-walled workpieces [14]. The issues emerging in the machining of thin-walled elements, e.g., the shape and dimensional accuracy, the cutting forces, and the surface roughness, have been extensively described in the literature [15,16,17].…”

Section: Introductionmentioning

confidence: 99%

Measurements of Forces and Selected Surface Layer Properties of AW-7075 Aluminum Alloy Used in the Aviation Industry after Abrasive Machining

2019

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Measurements of forces during machining, especially thin-walled structures typical of the aviation industry, are important in the aspect of instability caused by vibration. One of the last stages of manufacturing by machining is the finishing treatment and deburring of the product’s edges. Brushes with ceramic fibres are often employed in deburring, especially for large-sized elements specific to the aviation industry due to the possibility of automatic machining directly on machining centres. This study set out to analyse the effect of variable brushing conditions on axial forces and the selected surface layer properties of AW-7075 aluminium alloy. Experimental studies have examined factors such as surface roughness and topography, axial cutting force in ceramic brush treatment and surface free energy in the aspect of adhesive joints. The tested variable process parameters were the fibre material and the adjustment sleeve spring stiffness. Based on the tests, it was found that the axial force applied by the brush was more strongly connected with the spring stiffness rather than the type of bristle. For most cases, an increase in the value of free surface energy after brushing was observed compared to the initial machining which was milling.

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Assessment of the Accuracy of High-Speed Machining of Thin-Walled EN AW-2024 Aluminium Alloy Elements Using Carbide Milling Cutter and with PCD Blades

Cited by 9 publications

References 6 publications

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

Measurements of Forces and Selected Surface Layer Properties of AW-7075 Aluminum Alloy Used in the Aviation Industry after Abrasive Machining

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