Analysis of Surface Integrity and Dimensional Accuracy During Thin-Wall Machining

2017 ◽  
pp. 681-688
Author(s):  
Gururaj Bolar ◽  
Argha Das ◽  
Shrikrishna N. Joshi
Keyword(s):  
Surface Integrity ◽  
Dimensional Accuracy ◽  
Thin Wall

The Effect of Electromagnetic Pulse Treatment on Thin – Wall Bearing Ferrules Dimensional Accuracy

2014 ◽  
Vol 887-888 ◽  
pp. 1328-1332
Author(s):  
Wang Biao Qiu ◽  
Wei Xing Chen
Keyword(s):  
Residual Stress ◽  
Electromagnetic Pulse ◽  
Optical Measurement ◽  
Dimensional Accuracy ◽  
Magnetic Treatment ◽  
Thin Wall ◽  
Pulse Treatment ◽  
The Difference ◽  
The Stability ◽  
Frequency Pulse

The article based on different frequency pulse equiponderance electromagnetic destressing comparison experiment, using vertical optical measurement to survey the changes of bearing ferrules size, study the difference between the effect of different frequency electromagnetic in removing residual stress, find the frequency of magnetic treatment pulse that help to maintain the stability of the thin-wall bearing collars' size, effectively improve the cycle of bearing ferrules process .

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Experimental Study on Surface Integrity, Dimensional Accuracy, and Micro-Hardness in Thin-Wall Machining of Aluminum Alloy

2018 ◽  
Vol 5 (2) ◽  
pp. 13-31
Author(s):  
Gururaj Bolar ◽  
Shrikrishna N. Joshi
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Micro Hardness ◽  
Wall Deflection ◽  
High Feed ◽  
Axial Depth

This article presents an experimental investigation into the influence of process parameters viz. feed per tooth, axial depth of cut on milling force, surface finish, wall deflection and micro-hardness during thin-wall machining of an aerospace grade aluminum alloy 2024-T351. Results revealed that the process parameters significantly influence the surface finish and dimensional accuracy of machined thin-walls. High feed rate promoted the formation of built-up-edge (BUE). Combination of high feed and axial depth of cut aided in catastrophic failure of tools. Surface damages such as material plucking, material shearing, material adhesion and deformed feed mark layer formation were observed. Axial depth of cut negatively influenced the wall deflection leading to loss of dimensional accuracy. Interestingly, the micro-hardness at the machined surface was found to be lower than that of the bulk material hardness. These results will be useful in selection of suitable process parameters for quality and precise machining of thin-wall parts.

scholarly journals Experimental investigation and optimization of wall deflection and material removal rate in milling thin-wall parts

2021 ◽  
Vol 8 ◽  
pp. 17
Author(s):  
Gururaj Bolar ◽  
Shrikrishna Nandkishor Joshi
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Wall Deflection ◽  
Radial Depth ◽  
Tool Diameter

The selection of optimal process parameters is essential while machining thin-wall parts since it influences the quality of the product and affects productivity. Dimensional accuracy affects the product quality, whereas the material removal rate alters the process productivity. Therefore, the study investigated the effect of tool diameter, feed per tooth, axial and radial depth of cut on wall deflection, and material removal rate. The selected process parameters were found to significantly influence the in-process deflection and thickness deviation due to the generation of unfavorable cutting forces. Further, an increase in the material removal rate resulted in chatter, thus adversely affecting the surface quality during the final stages of machining. Considering the conflicting nature of the two performance measures, Non-dominated Sorting Genetic Algorithm-II was adopted to solve the multi-objective optimization problem. The developed model could predict the optimal combination of process variables needed to lower the in-process wall deflection and maintain a superior surface finish while maintaining a steady material removal rate.

scholarly journals A Real-Time Method to Detect the Deformation Behavior during Laser Solid Forming of Thin-Wall Structure

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 508 ◽  
Author(s):  
Hua Tan ◽  
Yuguang Chen ◽  
Zhe Feng ◽  
Wei Hou ◽  
Wei Fan ◽  
...  
Keyword(s):  
Real Time ◽  
Deformation Behavior ◽  
Detection Method ◽  
Dimensional Accuracy ◽  
Deposition Process ◽  
Wall Structure ◽  
Thin Wall ◽  
Time Deformation ◽  
Laser Solid Forming ◽  
Real Time Detection

Laser solid forming (LSF) is a promising additive manufacturing technology. In the LSF process, deformation behaviors dictate the accuracy of the produced parts. In this study, by using a laser displacement detector based on laser triangulation principle, an accurate and effective real-time detection method was established to monitor the real-time deformation behavior of the key position during the LSF of a thin-wall structure. The results confirmed that increasing thin-wall length results in increasing final deformation of the edge. The displacement fluctuation range and value in the middle of thin wall are both smaller than that of the positions near the end, while the entire displacement changing direction in the middle is opposite to that of the end positions. When the deposition process is paused, the deformation of the thin wall during the cooling stage will deviate the position of the deposited thin wall, resulting in the dislocation between the subsequent deposited part and that before the pause, which affect the dimensional accuracy of the thin wall structure. This non-contact real-time detection method also confirmed the ability to monitor the initiation of cracking during the LSF process, and a potential to be used for the on-line feedback control of deformation of detected key position of deposited structure.

Benchmarking the complex geometric profiles, dimensional accuracy and surface analysis of printed parts

2019 ◽  
Vol 26 (2) ◽  
pp. 319-329 ◽  
Author(s):  
Paridhi Subbaian Kaliamoorthy ◽  
Rajkumar Subbiah ◽  
Joseph Bensingh ◽  
Abdul Kader ◽  
Sanjay Nayak
Keyword(s):  
Surface Roughness ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Measuring System ◽  
Experimental Result ◽  
Complex Geometries ◽  
Thin Wall ◽  
Content Type ◽  
Metal Parts ◽  
Cooling Channels

Purpose Additive manufacturing has paved a way for geometrical freedom and mass customization of new and innovative products. However, it has a few limitations in printing complex geometries and sizes. The purpose of this paper is three-dimensional printing of metal parts using selective laser melting (SLM) has several intricacies. Design/methodology/approach To test the capabilities of SLM, the complex geometries of varying sizes, orientations, shapes such as square and cylindrical features, thin wall structures and holes were checked for dimensional accuracy and surface roughness. Findings The outcome of the study represents the capabilities of SLM and provide insight for solving the technological issues and processing constraint in the manufacture of metal parts from aluminum alloy. The analysis has proven that there is significant accuracy in dimension for large features in comparison with smaller one. The dimensional reproducibility was determined with the aid of an optical measuring system and the range of errors were calculated. These results show that the dimensional accuracy of the features in the printed part was within acceptable tolerance limits. This paper also investigated the significant contributing factors influencing printing of two and three-dimensional surface roughness based on the result of surface profilometer and it was observed that the surface was smoothened with the presence of overhangs and supports. Originality/value The ability of SLM to fabricate conformer cooling channels to support mould fabrication was tested. From the experimental result, it was observed that the quality of printing of conformal cooling channels depended on the diameter of channels with larger distortions in the channel having smaller diameter. The innovative aspect of the work was the study of build orientation combined with the investigated material.

Investigation into High-Speed/Super-High Speed Grinding

2011 ◽  
Vol 189-193 ◽  
pp. 4108-4111 ◽  
Author(s):  
Ya Li Hou ◽  
Chang He Li ◽  
Guo Yu Liu
Keyword(s):  
Surface Integrity ◽  
High Speed ◽  
High Efficiency ◽  
Dimensional Accuracy ◽  
Abrasive Machining ◽  
Machining Processes ◽  
Finishing Process ◽  
Key Technologies ◽  
High Speed Grinding ◽  
Advanced Machining

Abrasive machining is a widely employed finishing process for different-to-cut materials such as metals, ceramics, glass, rocks, etc to achieve close tolerances and good dimensional accuracy and surface integrity. High speed and super-high speed abrasive machining technologies are newest developed advanced machining processes to satisfy super-hardness and difficult-to-machining materials machined. In the present paper, high-speed/super-high speed abrasive machining technologies relate to ultra high speed grinding, quick-point grinding, high efficiency deep-cut grinding were analyzed. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies and the newest development and current states of high speed and super-high speed abrasive machining were investigated. It is concluded that high speed and super-high speed abrasive machining are a promising technology in the future.

A comprehensive investigation on machining of composites by EDM for microfeatures and surface integrity

2021 ◽  
pp. 251659842110633
Author(s):  
Suresh Gudipudi ◽  
Selvaraj Nagamuthu ◽  
Kanmani Subbu Subbian ◽  
Surya Prakasa Rao Chilakalapalli
Keyword(s):  
Surface Integrity ◽  
Discharge Current ◽  
Material Removal ◽  
Removal Rate ◽  
Principal Component ◽  
Dimensional Accuracy ◽  
Local Optimum ◽  
Machined Surface ◽  
Input Parameters ◽  
Grey Relation

In electro-discharge machining (EDM), the material removal takes place by precisely controlled sparks that occur between tool and workpiece separated with a spark gap in the presence of a dielectric. Generally, the non-contacting type and less material removal rates are attributed to attain a good surface finish and close dimensional tolerances during an EDM of monolithic metals and alloys. But the dimensional accuracy and surface integrity parameters would considerably affect during EDM of composites due to the existence of more than one material phase constituents. Therefore, the present work aims to study and optimize the performance characteristics under various EDM conditions employed in making rectangular channels on AA6061-B4C composite material. Initially, AA6061-4wt.%B4C composites were fabricated by ultrasonically assisted stir-casting, and the improved properties were obtained from various mechanical characterizations. The EDM experiments were conducted according to the full factorial experimental design. The three levels of input conditions such as discharge Current (I), discharge duration (T On), and discharge idle time (T Off) were considered. The considered output responses are material removal rate (MRR),taper (θ) of the machined channel, tool wear rate (TWR), average surface roughness (R) of the machined surface, and average recast layer thickness (ARLT) of the machined zone. These responses are co-related with multi-objective types in the sense that the MRR has to be maximized with all other responses minimized. Hence, principal component analysis (PCA) coupled with grey relation analysis (GRA) was used for optimization in which the results were normalized, and all the responses were converted into a single response named weighted grey relation grade (WGRG) for each trial. The experimental trial, which had the highest WGRG, was considered as a local optimum. The global optimum parameters were obtained by performing the Taguchi method (TM) (higher-the-better) for the maximization of WGRG. The analysis of variance (ANOVA) was performed to know the contribution of each EDM parameter toward the WGRG. The optimum levels of Current, T On, and T Off were identified as 8 A, 25 µs, and 36 µs, respectively. Results showed that all three input parameters significantly affected the WGRG, and a higher contribution of Current (52.11%) followed by the T On (26.72%) was observed. The interaction between the Current and T Off was found to be greater than other interactions. Taper values were observed to be reduced at the combination of 8 A discharge Current and 25 µs T On. None of the input parameters significantly affected the Ra, except for Current, which showed a slight effect. ARLT values showed an increasing trend of T On from 25 µs to 45 µs but decreased slightly at 65 µs for all Current levels. The moderate Current level 6 A was observed to be favorable in reducing ARLT when compared to low (4 A) and high (8 A) for all Ton values.

Machining of Thin Walls and Thin Floor Aerospace Components Made of Aluminum Alloy with High Aspect Ratio

2015 ◽  
Vol 830-831 ◽  
pp. 112-115 ◽  
Author(s):  
Anil Kumar Jain ◽  
Kasala Narasaiah ◽  
Shibu Gopinath
Keyword(s):  
Aluminum Alloy ◽  
Aspect Ratio ◽  
High Aspect Ratio ◽  
High Speed ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Raw Material ◽  
Thin Wall ◽  
High Speed Machining ◽  
Static And Dynamic Analysis

In present scenario most of airframe components employ aluminum alloy materials having wall thickness of 1.2 to 3mm. With advancement of manufacturing techniques such as high speed machining, it is possible to machine components with wall/floor thickness up to 0.3 to 0.5 mm with high aspect ratio. The aim of making such parts is to reduce weight of payload. The machining of monolithic structure involves removing of material up to 95% from the raw material. The objective of the study is to achieve maximum material removal rate without compromise on geometry, dimensional accuracy while machining the part. This paper proposes a working methodology for high speed machining which includes efficient process planning, based on static and dynamic analysis. This paper provides insight knowledge of selection of cutting tool, fixture design, clamping method, cutting process parameters; machine tool and computer aided manufacturing (CAM) strategy, optimum stock for minimal bending and distortion. This technology has been demonstrated in hexagonal test specimen of 0.5 mm thin wall and also proven on the indigenous developed global positioning system (GPS) components.

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