Ultrasonic-assisted friction drilling process of aerospace aluminum alloy (AA7075): FEA and experimental study

Baraheni, Mohammad; Bami, Alireza Bagheri; Alaei, Ali; Amini, Saeid

doi:10.1016/j.ijlmm.2021.03.001

Cited by 10 publications

(5 citation statements)

References 24 publications

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“…In this study, full factorial design was used to observe and identify any changes in the response due to the changes made to the variables [ 26 ]. This is a reliable and efficient approach due to its ability to discover the main effect of each factor as well as the interaction between all factors of the process, thereby achieving the optimal conditions [ 23 , 24 , 25 ].…”

Section: Modeling and Simulationmentioning

confidence: 99%

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Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

et al. 2021

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The use of external fixation devices is considered a valuable approach for the treatment of bone fractures, providing proper alignment to fractured fragments and maintaining fracture stability during the healing process. The need for external fixation devices has increased due to an aging population and increased trauma incidents. The design and fabrication of external fixations are major challenges since the shape and size of the defect vary, as well as the geometry of the human limb. This requires fully personalized external fixators to improve its fit and functionality. This paper presents a methodology to design personalized lightweight external fixator devices for additive manufacturing. This methodology comprises data acquisition, Computer tomography (CT) imaging analysis and processing, Computer Aided Design (CAD) modelling and two methods (imposed predefined patterns and topology optimization) to reduce the weight of the device. Finite element analysis with full factorial design of experiments were used to determine the optimal combination of designs (topology optimization and predefined patterns), materials (polylactic acid, acrylonitrile butadiene styrene, and polyamide) and thickness (3, 4, 5 and 6 mm) to maximize the strength and stiffness of the fixator, while minimizing its weight. The optimal parameters were found to correspond to an external fixator device optimized by topology optimization, made in polylactic acid with 4 mm thickness.

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Section: Modeling and Simulationmentioning

confidence: 99%

“…In such cases, DoE is a relevant technique as the optimization process requires the use of multiple parameters and the understanding of their correlations. However, despite being used for a wide range of industrial applications [ 23 , 24 , 25 ], DoE has not been used for the design and optimization of bone fixation devices.…”

Section: Introductionmentioning

confidence: 99%

Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

et al. 2021

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“…They measured the axial forces and the hardness of the new surface. They stated that with high Vc and low f, the forces decreased and the hardness increased (Baraheni et al, 2021). Luo et al stated that the effects of f and spindle speed on the drilling were investigated experimentally and by FEA.…”

Section: Introductionmentioning

confidence: 99%

“…They measured the axial forces and the hardness of the new surface. They stated that with high Vc and low f, the forces decreased and the hardness increased (Baraheni et al ., 2021). Luo et al .…”

Section: Introductionmentioning

confidence: 99%

Mathematical modeling and multiresponse optimization to reduce surface roughness and adhesion in Al 5083 H116 alloys used in ammunition propulsion actuators

Gökçe

Biberci²

2023

MMMS

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PurposeThis study aims to obtain the lowest surface roughness (Ra) and drill bit adhesion values (AV) depending on the change in control factors (cutting speed-Vc, feed rate-f and drill bit-D) during drilling of the Al 5083 H116 alloy. Low roughness values increase the fatigue strength of the final part and affect tribological properties such as lubrication and friction. In the machining of ductile materials, the AV increases the Ra value and negatively affects the tool life.Design/methodology/approachDrilling tests were conducted using Taguchi L16 orthogonal array. The experimental measurement findings for Ra and AV were adjusted utilizing the Grey Relational Analysis (GRA), the Response Surface Method (RSM) and Artificial Neural Networks (ANN) to generate prediction values. SEM detected drill-tip adhesions and chip morphology and they were analyzed by EDX.FindingsRa and AV increased as the f increased. Vc affects AV; 86.04% f on Ra and 54.71% Vc on AV were the most effective control parameters. After optimizing Ra and AV using GRA, the f is the most effective control factor. Vc: 120 m/min, f: 0.025 mm/rev and D2 were optimal. ANN predicted with Ra 99.6% and AV 99.8% accurately. Mathematical models are obtained with RSM. The increase in f increased AV, which had a negative effect on Ra, whereas the increase in Vc decreased the adhesion tendency. With the D1 drill bit with the highest flute length, a relatively lower Ra was measured, as it facilitates chip evacuation. In addition, the high correlations of the mathematical models obtained indicate that the models can be used safely.Originality/valueThe novelty of this study is to determine the optimum drilling parameters with GRA and ANN for drilling the necessary holes for the assembly of ammunition wing propulsion systems, especially those produced with Al 5083 H116 alloy, with rivets and bolts.

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“…This indicates lower axial forces when drilling with ultrasonic friction compared to conventional conditions. 17 Hsu et al 18 studied the effect of an ultrasonic condition at high-temperature machining on the properties of a nickel-based superalloy. They observed that ultrasonic milling at 40 kHz improved the surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Investigation of deviation and surface topography in ultrasonic vibration-assisted milling

Bayat

Amini

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Thin-walled structures have many applications in the aerospace industry. An important feature of them is their high strength to weight. When milling the thin-walled part, the thickness decreases step by step by cutting, which causes the process to be complex and dependent on process parameters. In the present study, thin-walled aluminum structures are investigated using conventional and ultrasonic milling processes, and distortion, surface roughness, surface texture, and average thin-wall forces are also investigated. Therefore, 18 tests are performed on parts made of 7075T6 aluminum alloy using various feeds, spindle speeds, and machining modes. The results showed that the machining type and spindle speed had 47% and 33% effect on distortion, respectively. In addition, the results showed that by applying vibrations to the milling, the amount of distortion can be reduced by up to 30% and effectively optimized. This technique is suitable for manufacturing industries that require high dimensional accuracy. Also, the surface texture and burr formation are investigated. In particular, the surface roughness in ultrasonic milling decreased compared to conventional milling.

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Ultrasonic-assisted friction drilling process of aerospace aluminum alloy (AA7075): FEA and experimental study

Cited by 10 publications

References 24 publications

Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

Optimization of a Patient-Specific External Fixation Device for Lower Limb Injuries

Mathematical modeling and multiresponse optimization to reduce surface roughness and adhesion in Al 5083 H116 alloys used in ammunition propulsion actuators

Investigation of deviation and surface topography in ultrasonic vibration-assisted milling

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