Metrological analysis of surface quality aspects in minimum quantity cooling lubrication

Maruda, Radosław W.; Wojciechowski, Szymon; Szczotkarz, Natalia; Legutko, Stanisław; Mia, Mozammel; Gupta, Munish Kumar; Niesłony, P.; Królczyk, Grzegorz M.

doi:10.1016/j.measurement.2020.108847

Cited by 41 publications

(14 citation statements)

References 47 publications

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“…Many previous works have also been devoted to different strategies for implementing cooling and lubrication of the cutting process of aluminium alloys and their effect on the surface quality after machining [ 43 , 44 ]. Maruda et al [ 45 ] presented a study on the effect of minimum quantity lubrication and surface roughness in the turning process. Jebaraj et al [ 46 ] studied the effect of cryogenic CO 2 and LN 2 coolants on the milling of aluminium alloy and found that the conventional fluid coolant offers a better surface roughness value ( Ra ) over cryogenic coolants.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.

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Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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“…The surface topography after machining has a strong influence on fatigue strength and other tribological properties [ 36 , 37 , 38 ]. Depending on the type of treatment used, the properties of the surface topography may differ significantly despite similar values of the typical parameters describing surface roughness, such as Ra.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Prediction Models of the Microwire EDM Process of Inconel 718 Using ANN and RSM Methods

2022

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Precise machining of micro parts from difficult-to-cut materials requires using advanced technology such as wire electrical discharge machining (WEDM). In order to enhance the productivity of micro WEDM, the key role is understanding the influence of process parameters on the surface topography and the material’s removal rate (MRR). Furthermore, effective models which allow us to predict the influence of the parameters of micro-WEDM on the qualitative effects of the process are required. This paper influences the discharge energy, time interval, and wire speed on the surface topography’s properties, namely Sa, Sk, Spk, Svk, and MRR, after micro-WEDM of Inconel 718 were described. Developed RSM and ANN model of the micro-WEDM process, showing that the discharge energy had the main influence (over 70%) on the surface topography’s parameters. However, for MRR, the time interval was also significant. Furthermore, a reduction in wire speed can lead to a decrease in the cost process and have a positive influence on the environment and sustainability of the process. Evaluation of developed prediction models of micro-WEDM of Inconel 718 indicates that ANN had a lower value for the relative error compared with the RSM models and did not exceed 4%.

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“…Therefore, it is important to obtain a uniform surface of the sandwich structure with the desired roughness and surface topography. Surface roughness is affected by multiple parameters, such as the level of wear of the cutting tool, the levels of vibration, the stability of the machining process, and the cutting parameters [ 15 , 16 , 17 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Surface Roughness and Surface Uniformity of a Hybrid Sandwich Structure after Machining

Doluk

Rudawska²,

Miturska³

2022

Materials

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The parameters of surface roughness Ra, Rz and Rmax as well as surface topography Sa, Sz, Sp and Sv of the two-layer sandwich structure composed of an AW-2024 T3 aluminum alloy (Al) and a carbon-fiber-reinforced polymer (CFRP) were measured to determine an impact of the machining configuration (arrangement of the materials forming a sandwich structure) and the type of tool (presence of the tool coating) on the quality of the surface obtained through circumferential milling. The measurements revealed that milling produced different values of surface roughness for the aluminum alloy and the CFRP composite with values of 2D and 3D surface roughness being higher for the composite layer. The highest value of Ra of 1.10 µm was obtained for the surface of the CFRP composite using the CFRP/Al configuration and a TiAlN-coated tool. The highest values of the Rz (6.51 µm) and Rmax (8.85 µm) surface roughness parameters were also obtained for the composite layer using the same machining configuration and type of tool.

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Metrological analysis of surface quality aspects in minimum quantity cooling lubrication

Cited by 41 publications

References 47 publications

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Evaluation of Prediction Models of the Microwire EDM Process of Inconel 718 Using ANN and RSM Methods

Investigation of the Surface Roughness and Surface Uniformity of a Hybrid Sandwich Structure after Machining

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