Experimental and Computational Analysis of Machining Processes for Light-Weight Aluminium Structures

Abstract

Abstract. Different possible reasons for defects have to be considered in machining light-weight aluminum structures. In the machining process, the cutting power affecting the workpiece leads to a thermo-mechanical load that can cause undesirable workpiece deformations and thus shape deviations. Moreover, the microstructure and the machined surface can be influenced, which is detrimental to the later application of the structures. Previously conducted experimental and simulative investigations, estimated the circular milling process to be the most suitable machining operation that provides the best compromise between mechanical and thermal loads compared to drilling operations [1,2]. In this paper the results of machining end-cross-sections of an aluminum profile are presented. The machining was obtained by a milling process, which is demanding, because of the low profile stiffness. For this process it is important to know the effects of machining in view of the shape deviations. By means of a Finite-Element-Analysis the deformations of the profile web can be calculated as well as validated by experiments. Based on these results, the appropriate process parameter values for end machining can be defined.

Redistribution of residual stress in aluminum alloy plate and its effect on bending deformation

“…There has been a lot of research on deformation problems with thin-walled components by domestic and foreign scholars. Weinert [4,5] used finite element method for numerical analysis of the processing process of components and proposed an optimized processing strategy to control processing deformation. Liao Kai [6] measured the initial residual stress of aluminum alloy thin-walled frame members using the layered-cutting method and established a mechanical model of the influence of initial residual stress and processing residual stress on deformation.…”

Integrated simulation of the process chain composite extrusion–milling–welding for lightweight frame structures

“…So far, this modelling technique is lagging the ability to simulate the chip or burr formation. Here, the main aspect is on the analysis of the work-piece deformation and geometrical deviations [11].…”

Tool life model for Al2O3 particle reinforced MMCs using genetic expression programming

“…However, a limited number of studies on the MMCs reinforced with Al 2 O 3 particles have been reported with respect to tool wear, surface finish, particle size and volume fraction of particles using coated cutting tools. 8,[33][34][35][36] The main concern, when machining MMCs, is the extremely high tool wear due to the abrasive action of the ceramic particles. Therefore, materials of very high resistance to abrasive wear are often recommended.…”