Dimensional Deviations of Horizontal Thin Wall of Titanium Alloy Ti6Al4V Determined by Optical and Contact Methods

Abstract

Thin-walled structures are used in many industries. The need to use such elements is dictated by the desire to reduce the weight of the finished product, as well as to reduce its cost. The most common method of machining such elements is the use of milling, which makes it possible to make a product of almost any shape. However, several undesirable phenomena occur during the milling of thin-walled structures. The main phenomenon is a deformation of the thin wall resulting from its reduced stiffness. Therefore, it is necessary to control the dimensional and shape accuracy of finished products, which is carried out using various measuring instruments. The development of newer measuring methods such as optical methods is being observed. One of the newer measuring machines is the 3D optical scanner. In the present experiment, thin-walled samples in horizontal orientation of Ti6Al4V titanium alloy were machined under controlled cutting conditions. During machining, the cutting speed and feed rate were assumed constant, while the input factors were the tool and cutting strategy. This paper presents graphs of deviations in the determined cross-section planes of thin-walled structures using a 3D optical scanner and a coordinate measuring machine. A correlation was made between the results obtained from the measurement by the optical method and those determined by the contact method. A maximum discrepancy of about 8% was observed between the methods used.

Influence of Tools and Cutting Strategy on Milling Conditions and Quality of Horizontal Thin-Wall Structures of Titanium Alloy Ti6Al4V

“…The results presented in this work are part of a larger study. In an earlier paper [ 47 ], thin-wall deviations determined using contact (coordinate measuring machine) and optical methods (3D optical scanner) were reported.…”

Evaluation of the Surface Topography and Deformation of Vertical Thin-Wall Milled Samples from the Nickel Alloy Inconel 625

“…The adopted depths of cut and radial depths under these strategies are shown in Table 3. The material removal rate depends on the feed rate, depth of cut and feed depth [1,15,52,60], so it can be seen from the values presented that it is constant at 2.03 cm 3 /min in the present experiment, which is the basis for comparing the results between samples. Figure 3 shows a photo of an example sample prepared based on the described methodology.…”

“…In addition to the use of classical measurement methods, such as contact measurements using a coordinate measuring machine, interest in optical methods is evident [13,14]. The greatest advantages of optical methods are shorter measurement times and the possibility of the dimensional inspection of the entire product, rather than in a point or linear manner Materials 2024, 17, 295 2 of 29 as in the case of CMM [15][16][17]. One of the newer measuring devices using the optical method is the 3D optical scanner (GOM).…”

“…It is most commonly used in many industries to inspect components after the manufacturing process [18,19]. The possibility of using an optical scanner to measure thin-walled components with small dimensions was presented in study [1], while in study [15], we presented the correlation of results obtained using a 3D optical scanner and a coordinate measuring machine. In study [15], samples with thin walls in a horizontal orientation were tested, for which a maximum measurement discrepancy of 8% was obtained between the methods used.…”