Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024-T6

Bayat, Masuod; Amini, Saeid; Hadidi, Mohsen

doi:10.1080/10426914.2021.1926496

Cited by 27 publications

(12 citation statements)

References 34 publications

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“…The results presented in the previous study by Bayat et al, 27 including runout, roughness, and straightness, have been used. In this paper, the results of tensile residual stress were added to the previous study, and the effect of these cases on each other was investigated.…”

Section: Methodsmentioning

confidence: 99%

“…As the review of previous studies showed, the application of ultrasonic vibrations in most cases has improved the output parameters in the process of ultrasonic turning compared to conventional turning, which in general can lead to the production of parts with reducing distortion and lower tensile residual stress, and resulting in improved quality and dimensional accuracy and less damage in production. Also, the previous study conducted by Bayat et al 27 showed that applying ultrasonic vibrations in the turning process reduced the workpiece’s distortion. However, the relationship between the residual stress and the amount of distortion is also important.…”

Section: Introductionmentioning

confidence: 92%

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Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Bayat

Amini

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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High accuracy in production parts and manufacturing quality are the requirements of production. Residual stress affects the surface quality and dimensional accuracy of manufactured parts. Production of parts with geometric tolerance, optimal residual stress, and suitable surface quality is always required by manufacturing industries. When machining parts, tensile residual stresses are created in them, which is one of the main reasons for the loss of geometric tolerances and distortion in the workpiece. This study investigated the effect of the ultrasonic-assisted vibration compared with conventional machining in various conditions of a 2024 aluminum workpiece on the surface quality, runout, straightness, and tensile residual stresses. In this article, the effects of geometric tolerance parameters, tensile residual stress, and surface roughness have been investigated simultaneously. A total of 18 experiments in different cutting speeds and feed rates in two machining states of conventional and ultrasonic vibration states were performed. The results showed that ultrasonic vibrations could be used to achieve 31% lower run out and 36% lower straightness in the parts. Also, the values of tensile residual stress in the ultrasonic vibration machining were 11% lower compared to conventional machining. Ultrasonic vibrations can also be used in most cases to achieve better surface quality, tolerance, and tensile residual stress according to machining parameters compared to conventional machining. The experimental results show that ultrasonic-assisted turning is a reliable method for machining, which can obtain lower tensile residual stress and improve the machined surface integrity and better tolerances.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 92%

Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Bayat

Amini

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…It avoids environmental pollution and human health; [11][12][13][14]44] 2) Good machinability: The melting point of Bi is very low (271.3 °C). In dry cutting process, the cutting temperature is higher [45,46] and large amounts of heat are generated by cutting friction melt Bi in chips to lubricate the cutting tool, avoid overheating, and further avoid the occurrence of cutting nodulation. Hence, liquid Bi plays a role in lubrication and melting embrittlement; and 3) Small quantity: The additional amount of Bi in steel only half of that of Pb can nearly achieve same machinability.…”

Section: Bismuthmentioning

confidence: 99%

“…Previous research indicated that in dry cutting, the cutting temperature was above 300 °C. [45,46] Hence, Bi softened and melted in chip in cutting.…”

Section: Effect Of Bismuth On the Machinability Of Steelmentioning

confidence: 99%

Forms and Roles of Bismuth in Steel: A Review

Xie

2022

steel research int.

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Bismuth (Bi), as a green free-cutting metal element, has been used for the production of free-cutting steels in the field of free-cutting steel for a couple of decades. One of the merits of bismuth is to improve the machinability of steel, while more Bi addition to steel causes cracking of steels during thermal rolling, attributed to the formation of liquid Bi films. Due to a lack of summary, people have limited mastering the Bi-bearing steels. Herein, the forms and roles of Bi in steel based on the literature survey are summarized. These specific reviews concentrate on the forms, mechanical properties, segregation, solidification, and solubility of Bi in steel, and the effect on grain, machinability, and thermal expansion of steel is also reviewed. This review is of great significance in advancing the understanding of Bi-bearing steels.

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“…For many, many researchers have studied the residual stresses and part distortion during product manufacturing. 5,6 Vibration combined with traditional machining has a positive effect on many conditions in many applications. 7,8 Sridhar and Poosa 9 studied the effect of machining parameters t on the degree of distortion and the results showed that distortion occurred at thicknesses less than 3 mm.…”

Section: Introductionmentioning

confidence: 99%

Investigation of deviation and surface topography in ultrasonic vibration-assisted milling

Bayat

Amini

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Thin-walled structures have many applications in the aerospace industry. An important feature of them is their high strength to weight. When milling the thin-walled part, the thickness decreases step by step by cutting, which causes the process to be complex and dependent on process parameters. In the present study, thin-walled aluminum structures are investigated using conventional and ultrasonic milling processes, and distortion, surface roughness, surface texture, and average thin-wall forces are also investigated. Therefore, 18 tests are performed on parts made of 7075T6 aluminum alloy using various feeds, spindle speeds, and machining modes. The results showed that the machining type and spindle speed had 47% and 33% effect on distortion, respectively. In addition, the results showed that by applying vibrations to the milling, the amount of distortion can be reduced by up to 30% and effectively optimized. This technique is suitable for manufacturing industries that require high dimensional accuracy. Also, the surface texture and burr formation are investigated. In particular, the surface roughness in ultrasonic milling decreased compared to conventional milling.

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Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024-T6

Cited by 27 publications

References 34 publications

Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Forms and Roles of Bismuth in Steel: A Review

Investigation of deviation and surface topography in ultrasonic vibration-assisted milling

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