Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Thin-walled elements are widely used in the aerospace industry, where the aim is to reduce the process time and the weight of the structure while ensuring the sufficient quality of the finished product. Quality is determined by geometric structure parameters and dimensional and shape accuracy. The main problem encountered during the milling of thin-walled elements is the deformation of the product. Despite the various methods available for measuring deformation, more are still being developed. This paper presents selected surface topography parameters and deformation of vertical thin-walled elements during an experiment under controlled cutting conditions for samples from titanium alloy Ti6Al4V. Constant parameters of feed (f), cutting speed (Vc,) and tool diameter (D) were used. Samples were milled using a tool for general-purpose and a tool for high-performance machining, as well as two different machining approaches: with greater involvement of face milling, and cylindrical milling with a constant material removal rate (MRR). For samples with vertical thin walls, the parameters of waviness (Wa, Wz,) and roughness (Ra, Rz) were measured using a contact profilometer in the selected areas on both processed sides. Deformations were determined in selected cross-sections perpendicular and parallel to the bottom of the sample using GOM measurement (GOM—Global Optical Measurement). The experiment showed the possibility of measuring deformations and deflection arrows of thin-walled elements proceeded from titanium alloy using GOM measurement. Differences in selected surface topography parameters and deformations were observed for the machining methods used with an increased cross-section of the cut layer. A sample with a deviation of 0.08 mm from the assumed shape was obtained.

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“…The interest in thin-walled machining is the subject of analysis by researchers. The data provide important information for the industry [13,14].…”

Section: Introductionmentioning

confidence: 99%

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

et al. 2023

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“…Due to the fact that composite materials have also been used as thin-walled elements, this aspect is the subject of this research. They are a very good alternative to thin-walled structures made of aluminum and titanium alloys [ 24 , 25 ], where it is necessary to ensure high stiffness and strength with a relatively low specific weight. Previous simulations of milling thin-walled composite structures based on FEM analysis enabled the analysis of the milling process plan, taking into account the impact of machining parameters [ 26 ].…”

Section: Introductionmentioning

confidence: 99%

Machinability Measurements in Milling and Recurrence Analysis of Thin-Walled Elements Made of Polymer Composites

Ciecieląg

2023

Materials

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The milling of polymer composites is a process that ensures dimensional and shape accuracy and appropriate surface quality. The shaping of thin-walled elements is a challenge owing to their deformation. This article presents the results of milling polymer composites made of glass and carbon fibers saturated with epoxy resin. The milling of each material was conducted using different tools (tools with polycrystalline diamond inserts, physically coated carbide inserts with titanium nitride and uncoated carbide inserts) to show differences in feed force and deformation after the machining of individual thin-walled samples. In addition, the study used recurrence analysis to determine the most appropriate quantifications sensitive to changes occurring in milling different materials with the use of different tools. The study showed that the highest forces occurred in milling thin-walled carbon-fiber-reinforced plastics using uncoated tools and the highest feeds per revolution and cutting speeds. The use of a high feed per revolution (0.8 mm/rev) in carbon-fiber-reinforced plastics machining by uncoated tools resulted in a maximum feed force of 1185 N. A cutting speed of 400 m/min resulted in a force of 754 N. The largest permanent deformation occurred in the milling of glass-fiber-reinforced composite samples with uncoated tools. The permanent deformation value of this material was 0.88 mm. Low feed per revolution (0.1 mm/rev) resulted in permanent deformations of less than 0.30 mm for both types of materials. A change in feed per revolution had the most significant effect on the deformations of thin-walled polymer composites. The analysis of forces and deformation made it possible to conclude that high feed per revolution were not recommended in composite milling. In addition to the analysis of machining thin-walled composites, the novelty of this study was also the use of recurrence methods. Recurrence methods were used to determine the most appropriate quantifications. Determinism, averaged diagonal length and entropy have been shown to be suitable quantifications for determining the type of machined material and the tools used.

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“…The tip of the slide burnishing tool can be in the shape of a torus, cylinder, or spherical cap with a radius of 1 ÷ 4 mm. Slide burnishing allows for machining low-stiffness elements (e.g., thin-walled sleeves) [3], parts for pre-milling [44,45], small elements, hardened steels [46], objects with holes [47], and objects with galvanic-diffusion coatings [48]. Slide burnishing is widely used in the aerospace and automotive, among other industries [3].…”

Section: Introductionmentioning

confidence: 99%

Selected Properties of the Surface Layer of C45 Steel Samples after Slide Burnishing

Skoczylas,

Kłonica

2023

Materials

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This paper presents the experimental results of a study investigating the impact of the machining fluid type, the variable factor, used in slide burnishing on 2D and 3D surface roughness; surface topography; Abbott–Firestone curve shape; microhardness; and SFE (surface free energy). In the experiment, pre-ground, ringed samples of C45 steel were used. The results showed an over eight-fold decrease in the value of the Ra (arithmetical mean deviation) parameter and over a five-fold decrease in the Rt (total height of profile) parameter in relation to their values after grinding. The parameters Rpk (reduced peak height), Rk (core roughness depth), and Rvk (reduced valley depth) were also reduced. The Abbott–Firestone curve after slide burnishing changed its angle of inclination (it was more flattened), and the material ratio Smr increased. The reduction in the Rpk and Rk parameters and increased material ratio will most likely contribute to restoring the functionality of these surfaces (increased resistance to abrasive wear). After slide burnishing, the maximum 25% increase in microhardness was obtained compared to the value after grinding, while the layer thickness was 20 μm. The surface energy of elements subjected to slide burnishing using various machining fluids slightly increased, or its value was close to that of the ground surface. The most favourable properties of the surface layer in terms of mating between two elements were obtained for a part that was slide-burnished with a mixture of oil + polymethyl methacrylate (PMM) + molybdenum disulphide (MoS2).

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Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Cited by 15 publications

References 69 publications

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

Investigation of Selected Surface Topography Parameters and Deformation during Milling of Vertical Thin-Walled Structures from Titanium Alloy Ti6Al4V

Machinability Measurements in Milling and Recurrence Analysis of Thin-Walled Elements Made of Polymer Composites

Selected Properties of the Surface Layer of C45 Steel Samples after Slide Burnishing

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