Measurements of Forces and Selected Surface Layer Properties of AW-7075 Aluminum Alloy Used in the Aviation Industry after Abrasive Machining

Abstract

Measurements of forces during machining, especially thin-walled structures typical of the aviation industry, are important in the aspect of instability caused by vibration. One of the last stages of manufacturing by machining is the finishing treatment and deburring of the product’s edges. Brushes with ceramic fibres are often employed in deburring, especially for large-sized elements specific to the aviation industry due to the possibility of automatic machining directly on machining centres. This study set out to analyse the effect of variable brushing conditions on axial forces and the selected surface layer properties of AW-7075 aluminium alloy. Experimental studies have examined factors such as surface roughness and topography, axial cutting force in ceramic brush treatment and surface free energy in the aspect of adhesive joints. The tested variable process parameters were the fibre material and the adjustment sleeve spring stiffness. Based on the tests, it was found that the axial force applied by the brush was more strongly connected with the spring stiffness rather than the type of bristle. For most cases, an increase in the value of free surface energy after brushing was observed compared to the initial machining which was milling.

Ultimate Load-Carrying Ability of Rib-Stiffened 2024-T3 and 7075-T6 Aluminium Alloy Panels under Axial Compression

“…The 2000 series aluminium alloy grades are good for parts requiring good resistance to temperatures up to 150 °C. With the exception of grade 2219, these aluminium alloys have limited weldability [ 3 , 4 ], but some of the alloys in this series have excellent machinability [ 5 , 6 ]. EN AW-2024 [ 7 ] and EN AW-7075 [ 7 ] aluminium alloys are the most popular grades used in the aerospace industry for skins and wing spars, compressor blades, fan discs, gears and shafts, fuse parts, regulating elements of valves, and other parts of commercial aircraft and aerospace vehicles.…”

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

“…Currently, integral elements are manufactured mostly using state-of-the-art 5-axis machining centres by means of high-performance machining techniques, such as: HSC (High Speed Cutting) [ 6 ] and HPC (High Performance Cutting). They are very often produced using monolithic plates made of light metal alloys (aluminium, titanium) [ 7 ].…”

Selected Properties of the Surface Layer of C45 Steel Parts Subjected to Laser Cutting and Ball Burnishing

“…The phenomena that occur during ball burnishing result in the generation of mechanical energy, part of which is released in the form of heat, and the rest is stored in the material, causing an increase in its surface energy [ 23 ]. In addition, the geometric structure of the surface formed as a result of burnishing affects the energy state of the workpiece, leading to an increase in its adsorption activity and chemical activity [ 24 , 25 ].…”