Influence of milling process parameters and significance of tools to improve the surface quality of GFRP composites

Purpose For the laser powder bed fusion (L-PBF) technology, the side surface quality is essentially important for industrial applicated parts, such as the inner flow parts. Contour is generally adopted at the parts’ outline to enhance the side surface quality. However, the side surface roughness (Ra) is still larger than 10 microns even with contour in previous studies. The purpose of this paper is to study the influence of contour process parameters, laser power and scanning velocity on the side surface quality of the AlSi10Mg sample. Design/methodology/approach Using L-PBF technology to manufacture AlSi10Mg samples under different contour process parameters, use a laser confocal microscope to capture the surface information of the samples, and obtain the surface roughness Ra and the maximum surface height Rz of each sample after analysis and processing. Findings The results show that the side surface roughness decreases with the increase of the laser power at the fixed scanning velocity of 1,000 mm/s, the side surface roughness Ra stays within the error range as the contour velocity increases. It is found that the Ra increases with the scanning velocity increasing and the greater the laser power with the greater Ra increases when the laser power of contour process parameters is 300 W, 350 W and 400 W. The Rz maintain growth with the contour scanning velocity increasing at constant laser power. The continuous uniform contour covers the pores in the molten pool of the sample edge and thus increase the density of the sample. Two mechanisms named “Active adhesion” and “Passive adhesion” cause sticky powder. Originality/value Formation of a uniform and even contour track is key to obtain the good side surface quality. The side surface quality is determined by the uniformity and stability of the contour track when the layer thickness is fixed. These research results can provide helpful guidance to improve the surface quality of L-PBF manufactured parts.

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Ultraschallüberlagertes Trennschleifen von Faserverbundwerkstoffen*/Ultrasound abrasive cutting of fiber composites - Survey on the potential and mode of action

wt Werkstattstechnik online ◽

10.37544/1436-4980-2016-01-02-41 ◽

2016 ◽

Vol 106 (01-02) ◽

pp. 39-43

Author(s):

Y. Babenko ◽

T. Mayer ◽

A. Gebhardt

Keyword(s):

Surface Quality ◽

Process Parameters ◽

Mode Of Action ◽

Fiber Composites ◽

Cutting Process ◽

Force Analysis ◽

Abrasive Cutting

Dieser Fachartikel befasst sich mit der Untersuchung des Potentials der Ultraschallüberlagerung beim Trennschleifen moderner Faserverbundwerkstoffe. Es wurde eine Zerspankraftanalyse des Trennschleifprozesses am CFK-Werkstück mit variierenden Prozessparametern durchgeführt. Zudem wurden die Oberflächenqualitäten der Schnittkanten betrachtet.   The presented study describes the investigation of the potential of ultrasound abrasive cutting of modern fiber composites. A force analysis of the abrasive cutting process of CFRP was conducted, while the process parameters were varied. In addition, the surface quality of the machined workpieces was observed.

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ANALYSIS OF THE SURFACE QUALITY OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING

Journal of Engineering Studies and Research ◽

10.29081/jesr.v19i3.119 ◽

2016 ◽

Vol 19 (3) ◽

Author(s):

CRINA RADU ◽

EUGEN HERGHELEGIU ◽

ION CRISTEA ◽

CAROL SCHNAKOVSZKY

Keyword(s):

Surface Quality ◽

Process Parameters ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming ◽

Metal Sheets ◽

Vertical Step ◽

Tool Diameter ◽

Aluminium Metal

<p>The aim of the current work was to analyse the influence of the process parameters (tool diameter, size of the vertical step of tool, feed rate and spindle speed) on the quality of the processed surface, expressed in terms of roughness and macrostructure in the case of parts processed by single point incremental forming. The analysis was made on A1050 aluminium metal sheets. The obtained results revealed that the process parameters influence differently the surface quality, the worst influence being exerted by the increase of the vertical step of tool. </p>

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Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University ◽

10.1051/jnwpu/20183610124 ◽

2018 ◽

Vol 36 (1) ◽

pp. 124-131

Author(s):

Hongji Zhang ◽

Yuanyuan Ge ◽

Hong Tang ◽

Yaoyao Shi ◽

Zengsheng Li

Keyword(s):

Magnesium Alloy ◽

Surface Quality ◽

High Speed ◽

Milling Process ◽

Spindle Speed ◽

Feed Speed ◽

Milling Force ◽

High Speed Milling ◽

Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

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Optimizing Milling Process Parameters of Bovine Horns forMaximizing Surface Quality and Minimizing Power Consumption

Proceedings of the 2019 1st International Conference on Engineering and Management in Industrial System (ICOEMIS 2019) ◽

10.2991/icoemis-19.2019.49 ◽

2019 ◽

Author(s):

Audrey Unadi ◽

Teddy Sjafrizal ◽

Rino Anugraha ◽

Muhammad Iqbal

Keyword(s):

Power Consumption ◽

Surface Quality ◽

Process Parameters ◽

Milling Process

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Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

Metals ◽

10.3390/met10020289 ◽

2020 ◽

Vol 10 (2) ◽

pp. 289 ◽

Cited By ~ 1

Author(s):

Antonio Rubio-Mateos ◽

Asuncion Rivero ◽

Eneko Ukar ◽

Aitzol Lamikiz

Keyword(s):

Process Parameters ◽

Feed Rate ◽

Cutting Speed ◽

Milling Process ◽

Machining Process ◽

Butadiene Rubber ◽

Compression Tests ◽

Compressive Behavior ◽

Finishing Processes

In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.

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The Investigation of a Micro-Component Machined on a Custom-built Miniature Machine Tool

Jurnal Teknologi ◽

10.11113/jt.v59.2563 ◽

2012 ◽

Vol 59 (2) ◽

Author(s):

Syaimak Abdul Shukor

Keyword(s):

Surface Quality ◽

Milling Process ◽

Micro Milling ◽

Batch Size ◽

Geometrical Accuracy ◽

Custom Made ◽

Micro Parts ◽

Solid Carbide ◽

Steel Aisi

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining an “adapted standard‟ of micro-testpiece. The experiments have been carried out in two different materials: Carbon Steel (AISI 1040) and Titanium Alloyed (TiAl6V4) using solid carbide flat end mill cutters with 0.6mm diameter. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-parts can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality (Ra=0.04-0.07μm) and acceptable geometrical accuracy.

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