Machining aerospace aluminium alloy with cryo-treated and untreated HSS cutting tools

Adin, Mehmet Şükrü

doi:10.1080/2374068x.2023.2273035

Cited by 22 publications

(2 citation statements)

References 72 publications

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“…The current work is an optimization study of cutting conditions during dry end milling of AA5083, where the optimized geometry of the two-flute cutter is manufactured by a grinding 5-axis machine, as described in detail in Kechagias et al [17], and then the radial cutting depth, feed per tooth, and speed were tested in different dry cutting conditions. Note here that, in the literature, the majority of the research works utilized cutters from the market and not laboratorymade [35][36][37][38][39]. Therefore, the cutter geometry details were designed and optimized for the specified AA5083 alloy.…”

Section: Introductionmentioning

confidence: 99%

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

Kechagias

2024

Int J Adv Manuf Technol

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Surface integrity problems during selective material removal processes are a very common limitation for process productivity and part quality, especially in difficult-to-machine materials like 5083 aluminium alloy (AA), which is known for its remarkable performance in extreme environments. In general, tuning the cutting-part material properties with cutter geometry and cutting parameters can optimize surface texture, increase parts accuracy and resistance in corrosion, and eliminate process noise and energy waste. This work is an experimental study of surface parameter optimization during finish end milling of an AA5083 under a specific range of three cutting parameters with an optimized two-flute carbide cutter by previous work. So, twenty-seven experiments were run having varied the radial depth of cut (RDOC), feed rate (f), and cutting speed (S). Surface roughness parameters (Ra and Rt) were measured in the direction of cutting speed at three different distances by the upper edge. The signal-to-noise (SN) ratios have been calculated, and the process was optimized following the analysis of means. Then, additive models with linear interactions were fitted on SN ratios, and the analysis of variances and residual normality plots were utilized to validate the models’ goodness. The SN approach and analysis of means conclude that 0.5 mm RDOC, 6000 rpm speed, and 0.082 mm/tooth feed optimize the process and can effectively predict the Ra and Rt responses. The newly produced machinability data can benefit further applications of AA5083 in industrial applications such as shipbuilding and vehicle bodies.

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Section: Introductionmentioning

confidence: 99%

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

Kechagias

2024

Int J Adv Manuf Technol

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“…To mitigate the harmful effects of traditional machining, several sustainable strategies, such as minimum quantity lubrication (MQL), dry cutting, cryogenically treated tools, solid-lubricant assisted machining, air/ gas/vapor cooling, cryolubrication, optimization of cutting parameters, paths, adaptive cutting, and high-speed machining, have been reported [17][18][19]. These strategies do not require mineral oil-based cutting fluids and show a reduction in environmental impact along with improved cutting tool life [20], lower cutting tool wear [21] better surface quality, lower cutting forces cutting energy [22], and improved productivity and cycle times [23,24].…”

Section: Introductionmentioning

confidence: 99%

Toward cleaner space explorations: a comparative life cycle assessment of spacecraft propeller tank manufacturing technologies

Kokare,

Moraes,

Fernandes

et al. 2024

Int J Adv Manuf Technol

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The traditional method of manufacturing propellant tanks for rockets and spaceships involves significant amounts of forging, and machining, making it expensive and environmentally unfriendly. A novel approach for manufacturing propellant tanks that reduces the need for machining and friction stir welding processes has been presented in this paper. This approach involves manufacturing a tank half starting from a single metal plate, using innovative and advanced metal forming processes such as hot stretch forming, magnetic pulse forming, hub forming, and integrated stiffened cylinder (ISC) flow forming followed by orbital welding of two tank halves. A life cycle assessment (LCA) study was conducted in accordance with ISO 14044:2006 standard using the ReCiPe 2016 Midpoint (H) method to compare the environmental impacts of the traditional and newly developed approaches for manufacturing propellant tanks. The results of the LCA study showed that the new approach based on advanced forming technologies reduced carbon footprint by 40%, cumulative energy demand by 35%, water footprint by 17%, and materials waste by 4% compared to traditional manufacturing. The lower environmental impact of the new approach was attributed to a decrease in friction stir welding requirements due to the implementation of advanced forming techniques that enable integrated tank production. This lowered the overall energy consumption in the novel approach by a factor of 1.5 and in turn resulted in lower environmental impact compared to traditional forging and machining-based method. Furthermore, a futuristic scenario that involves in-house tank production using the novel approach with minimal transportation of inventories was also simulated. Based on the LCA results, it was seen that the newly developed approach for manufacturing propellant tanks was more environmentally friendly than the traditional approach and its environmental footprint could be further reduced by implementing the futuristic scenario with minimal transportation. This novel approach is also expected to reduce the lead time and production cost of manufacturing a propellant tank. Hence, future efforts in cost assessment and further optimization of raw material and energy usage are recommended.

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Diametral error correction in turning slender workpieces: an integrated approach

Grossi,

Scippa,

Campatelli

2023

Int J Adv Manuf Technol

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Machining aerospace aluminium alloy with cryo-treated and untreated HSS cutting tools

Cited by 22 publications

References 72 publications

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

Toward cleaner space explorations: a comparative life cycle assessment of spacecraft propeller tank manufacturing technologies

Diametral error correction in turning slender workpieces: an integrated approach

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