Experimental investigation of cooling medium on submerged friction stir processed AZ31 magnesium alloy

Rathinasuriyan, C.; Mystica, A.; Sankar, R.; Kumar, V.S. Senthil

doi:10.1016/j.matpr.2020.11.575

Cited by 11 publications

(2 citation statements)

References 19 publications

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“…The increased hardness is attributed to the decrease in grain size and small particles of intermetallic compounds, while processed specimens submerged in water exhibit lower hardness [15]. The watercooled specimen for condition 2 shows lower hardness than the rest, suggesting that the meniscus force due to the surface tension of water between the abrasive disk and specimen has an effect on the hardness.…”

Section: Effect Of Medium On Microstructure Hardness and Tensile Stressmentioning

confidence: 99%

Surface texturing of fan-blade body by random-orbital polishing with in-line aqueous mist

Danaraj¹,

Yeo

2021

Int J Adv Manuf Technol

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Airfoil structures such as fan blades have free form geometry which require a high level of precision in order to create a uniform finish for ideal gas path flow. Challenges in machining of such parts have led to rework in order to remove defects and conform to dimensional requirements at the same time.Mechanical polishing is the most common method to remove surface irregularities on fan blades such as scallop height, while maintaining the required dimensions. After the polishing process, the part will undergo shot peening, vibratory finishing and later, painting and coating at the final stages. It is therefore essential for the fan blade surface to pre-treated with rough, uniform textures in order to promote good surface-to-surface adhesion at the end of the manufacturing cycle.Generally, the polishing process is assisted by an external cooling medium applied on the part surface at intervals. This method of removing heat is not effective, as the polished surface may experience scratches or distortion, especially around thin-walled sections of the leading edge in fan blade. The existing polishing method uses a single-axis rotary tool can produce average surface roughness, Ra, of 1.2 µm that satisfies the requirement. However, this form of aggressive polishing has a high material removal rate, resulting in excessive reduction in material thickness which leads to the rejection of costly fan blade.This study a new localized polishing method and examines its effect on the surface topography of an airfoil component made of aluminum alloy. The area of interest is focused on the leading edge of a fan blade at which polishing is carried out using a random-orbital polishing tool with modified features to incorporate internal cooling capability. Experimental trials are conducted to study the effects of surface finish with fixed grain abrasive disks under four conditions. A cold gun is connected in-line to guide cold air inside the internal passages of the tool and out onto the surface of the part directly. A secondary cooling source by water nozzle spray is integrated in the tool to mix with the cold air jet and form an aerosol mist during tool activation.Surface topography of the samples are determined by arithmetic mean deviation, maximum height and root mean square of the profile. Surface roughness was performed using an optical profilometer. The localized polishing method achieved a desirable surface roughness, Ra of 0.8 µm, while removing all traces of scallop height and maintaining the leading-edge thickness within tolerance. The study showed that the new method produced a topography that is uniformly textured. This method can improve the manufacturing cycle time.

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Section: Effect Of Medium On Microstructure Hardness and Tensile Stressmentioning

confidence: 99%

Surface texturing of fan-blade body by random-orbital polishing with in-line aqueous mist

Danaraj¹,

Yeo

2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…For the single-axis rotary polishing, the higher hardness can be attributed to the cutting speed of the tool, where the fixed direction generates a higher abrasive action. The increased hardness is attributed to the decrease in grain size and small particles of intermetallic compounds, while processed specimens submerged in water are known to exhibit lower hardness [30].…”

Section: Micro-hardness Analysismentioning

confidence: 99%

Mechanical polishing of fan blade by a prototype random-orbital tool

Danaraj¹

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Surface metal-matrix composites based on AZ91 magnesium alloy via friction stir processing: A review

Mirzadeh

2023

Int J Miner Metall Mater

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Experimental investigation of cooling medium on submerged friction stir processed AZ31 magnesium alloy

Cited by 11 publications

References 19 publications

Surface texturing of fan-blade body by random-orbital polishing with in-line aqueous mist

Surface texturing of fan-blade body by random-orbital polishing with in-line aqueous mist

Mechanical polishing of fan blade by a prototype random-orbital tool

Surface metal-matrix composites based on AZ91 magnesium alloy via friction stir processing: A review

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