Diamond tool wear during ultra-high precision machining of rapidly solidified aluminium RSA 905

Abou-El-Hossein, Khaled; Olufayo, Oluwole A.; Mkoko, Zwelinzima

doi:10.1016/j.wear.2012.12.060

Cited by 45 publications

(24 citation statements)

References 18 publications

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“…It is also important to note that in an industrial context, high precision turning avoids successive operations as turning + grinding or turning + grinding + honing or turning + grinding + polishing. Many studies have been devoted to high precision machining of aluminium alloys [6,7]. To reach a polish mirror (low surface roughness: R a = 5-10 nm), a singlecrystal diamond must be used.…”

Section: Characteristics Of High Precision Process and Machinesmentioning

confidence: 99%

High precision hard turning of AISI 52100 bearing steel

Revel

Jouini

Thoquenne

et al. 2016

Precision Engineering

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Section: Characteristics Of High Precision Process and Machinesmentioning

confidence: 99%

High precision hard turning of AISI 52100 bearing steel

Revel

Jouini

Thoquenne

et al. 2016

Precision Engineering

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“…The other one was made of RSP905, which is a fine grain size aluminium alloy having superior mechanical properties such as hardness and strength than conventional aluminium alloys [27]. Besides, it shows a good machining property by diamond turning and abrasive polishing [28,29]. Prior to polishing, the sample was fabricated with some rectangular microstructures on its surface as shown in Fig.…”

Section: Methodsmentioning

confidence: 99%

New vibration-assisted magnetic abrasive polishing (VAMAP) method for microstructured surface finishing

Guo

Kum

et al. 2016

Opt. Express

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In order to polish microstructured surface without deteriorating its profile, we propose a new vibration-assisted magnetic abrasive polishing (VAMAP) method. In this method, magnetic force guarantees that the magnetic abrasives can well contact the microstructured surface and access the corners of microstructures while vibration produces a relative movement between microstructures and magnetic abrasives. As the vibration direction is parallel to the microstructures, the profile of the microstructures will not be deteriorated. The relation between vibration and magnetic force was analyzed and the feasibility of this method was experimentally verified. The results show that after polishing, the surface finish around microstructures was significantly improved while the profile of microstructures was well maintained.

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“…Abou-El-Hossein et al also noted the improved surface roughness conditions with the increase in machining time as the tool wear flattened out after the initial stage of wear and predicted a possible increase in surface roughness values as the tool wear further deteriorates [18]. Hence, from our observation so far, it is safe to posit that an increase in AE spikes which corresponds to increased surface roughness values could occur with further significant increase in machining distance covered for RSA 443 alloy.…”

Section: Figure 10 Increasing Trend Of Ae Features and Wear With Surmentioning

confidence: 99%

“…Furthermore, tool wear investigation on ultra-high precision diamond turning RSA 905 alloy by Abou-el-hossein et al has revealed that minimum abrasion occurred at low feed but achieved a highest value at the middle range of feed for the selected levels of machining parameters [18]. A recent study on diamond insert wear while turning RSA 443 alloy revealed that reduced cutting speed degenerated to increased tool wear and higher surface roughness occurred at lower spindle speed while feed rate effect was not as significant as the spindle speed.…”

Section: Uhpdt Of Rapidly Solidified Aluminium Alloysmentioning

confidence: 99%

AE Monitoring of Diamond Turned Rapidly Soldified Aluminium 443

Onwuka

Abou-El-Hossein

Mkoko

2017

J. Phys.: Conf. Ser.

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Abstract. The fast replacement of conventional aluminium with rapidly solidified aluminium alloys has become a noticeable trend in the current manufacturing industries involved in the production of optics and optical molding inserts. This is as a result of the improved performance and durability of rapidly solidified aluminium alloys when compared to conventional aluminium. Melt spinning process is vital for manufacturing rapidly solidified aluminium alloys like RSA 905, RSA 6061 and RSA 443 which are common in the industries today. RSA 443 is a newly developed alloy with few research findings and huge research potential. There is no available literature focused on monitoring the machining of RSA 443 alloys. In this research, Acoustic Emission sensing technique was applied to monitor the single point diamond turning of RSA 443 on an ultrahigh precision lathe machine. The machining process was carried out after careful selection of feed, speed and depths of cut. The monitoring process was achieved with a high sampling data acquisition system using different tools while concurrent measurement of the surface roughness and tool wear were initiated after covering a total feed distance of 13km. An increasing trend of raw AE spikes and peak to peak signal were observed with an increase in the surface roughness and tool wear values. Hence, acoustic emission sensing technique proves to be an effective monitoring method for the machining of RSA 443 alloy.

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Diamond tool wear during ultra-high precision machining of rapidly solidified aluminium RSA 905

Cited by 45 publications

References 18 publications

High precision hard turning of AISI 52100 bearing steel

High precision hard turning of AISI 52100 bearing steel

New vibration-assisted magnetic abrasive polishing (VAMAP) method for microstructured surface finishing

AE Monitoring of Diamond Turned Rapidly Soldified Aluminium 443

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