Machinability study of aircraft series aluminium alloys 7075-T6 and 7050-T7451

2020 ◽  
Vol 44 (3) ◽  
pp. 427-439
Author(s):  
Ali Yeganefar ◽  
Seyed Ali Niknam ◽  
Victor Songmene
Keyword(s):  
Aluminium Alloy ◽  
Surface Quality ◽  
Aluminium Alloys ◽  
End Milling ◽  
Experimental Studies ◽  
Burr Formation ◽  
Limited Information ◽  
Milling Operations ◽  
Aluminium Alloy 7050 ◽  
Machining Operations

The aluminium alloy 7050-T7451 is generally considered as the principal choice in aeronautical applications demanding adequate strength, stress corrosion cracking resistance, and toughness. Surprisingly, despite extensive research works on machining and machinability of aluminium alloys, including aluminium alloy 7075-T6, limited information was found on machining and machinability evaluation of 7050-T7451, which belongs to a similar family as 7075-T6. To remedy the lack of knowledge determined, dry ball-end milling operations were performed with coated end milling tools on both materials. Experimental characterization and cutting force measurements were performed to measure/evaluate the cutting forces, burr formation morphology, insert performance (wear/breakage), and surface quality attributes. According to experimental studies, 7050-T7451 was found more machinable than 7075-T6. Less burr formation and better surface quality were observed on 7075-T6. Machining attributes are influenced by different experimental factors. However, other machinability attributes, including residual stress, vibration modes, as well as particle emission, must be studied under various lubrication modes and machining operations in subsequent studies. This also recalls further studies on simultaneous multiple response optimization.

Supervision of Tool Wear and Surface Quality During End Milling Operations

1994 ◽  
Vol 27 (4) ◽  
pp. 507-512 ◽  
Author(s):  
H. Konrad ◽  
R. Isermann ◽  
H.U. Oette
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Milling Operations

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

DECODING OF THE RELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (04) ◽  
pp. 1950054 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
End Milling ◽  
Complex Structure ◽  
Dry Machining ◽  
End Mill ◽  
Milling Operation ◽  
Machining Operations

Analysis of the surface quality of workpiece is one of the major works in machining operations. Variations of cutting force is an important factor that highly affects the quality of machined workpiece during operation. Therefore, investigating about the variations of cutting forces is very important in machining operation. In this paper, we employ fractal analysis in order to investigate the relation between complex structure of cutting force and surface roughness of machined surface in end milling operation. We run the machining operation in different conditions in which cutting depths, type of cutting tool (serrated versus square end mills) and machining conditions (wet and dry machining) change. Based on the obtained results, we observed the relation between complexity of cutting force and surface roughness of generated surface of machined workpiece due to engagement with the flute surface of end mill, in case of using square end mill in dry machining condition, and also in case of using serrated end mill in wet machining condition. The fractal approach that was employed in this research can be potentially examined in case of other machining operations in order to investigate the possible relation between complex structure of cutting force and surface quality of machined workpiece.

Experimental Investigation and Modeling of Milling Burrs

2013 ◽  
Author(s):  
Seyed Ali Niknam ◽  
Victor Songmene
Keyword(s):  
Computational Model ◽  
Material Properties ◽  
Aluminium Alloys ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Force Coefficient ◽  
Slot Milling ◽  
Part Quality ◽  
Cutting Force Coefficient ◽  
Machining Operations

The burr formation is one of the most common and undesirable phenomenon occurring in machining operations which reduces assembly and machined part quality. Therefore, it is desired to eliminate the burrs or reduce the effort required to remove them. This paper presents the results of an experimental study and describe the influence of cutting parameters on slot milling burrs, namely top burrs and exit burrs. Statistical methods are also used to determine the controllability of each burr. A computational model is then proposed to predict the exit up milling side burr thickness based on cutting parameters and material properties such as yield strength and specific cutting force coefficient that are the only unknown variables in the model. The proposed computational model is validated using experimental results obtained during slot milling of 2024-T351 and 6061-T6 aluminium alloys.

New Ways in Aluminium Alloys Grinding

2011 ◽  
Vol 496 ◽  
pp. 132-137 ◽  
Author(s):  
Martin Novák ◽  
Natasa Naprstkova ◽  
Ludek Ruzicka
Keyword(s):  
Surface Quality ◽  
Production Technology ◽  
Automotive Industry ◽  
Aluminium Alloys ◽  
Machined Surface ◽  
Milling Operations ◽  
Machined Surface Quality ◽  
Cutting Operation ◽  
Traditional Process

This paper deals with new possibilities in aluminium alloys grinding. Presently the aluminium alloys have forceful usage in engineering. The using of aluminium alloys we can find in general engineering, automotive industry, cosmonautics, aeronautics and medicine. Wide possibilities of the aluminium alloys using is very important area for production technology too. The traditional process of aluminium alloys is e. g. forming, pressing. In cutting operation is it especially turning and milling operations. Grinding like finishing method of machining is not so used for aluminium alloys machining. This method not doing optimal results in touch with these materials of machined surface quality. This paper shows new ways and possibilities in aluminium alloys grinding.

Condition Monitoring With Round Ceramic Inserts While Face Milling Using Acceleration Data

2010 ◽  
Author(s):  
Justin L. Milner ◽  
John T. Roth
Keyword(s):  
Condition Monitoring ◽  
End Milling ◽  
Low Cost ◽  
Milling Operations ◽  
Tool Monitoring ◽  
Wear Life ◽  
Acceleration Data ◽  
Life Tests ◽  
The Fourier Transform ◽  
Machining Operations

In order to automate machining operations, it is necessary to develop robust tool condition monitoring techniques. In this paper, a tool monitoring strategy for round whisker-reinforced ceramic end milling tools is presented based on the Fourier transform and statistical analysis of the vibrations of the tool during the machining operations. Using a low-cost tri-axial piezoelectric accelerometer, the presented algorithm demonstrates the ability to accurately monitor the condition of the tools as the wear increases during linear milling operations. One benefit of using accelerometer signals to monitor the cutting process is that the sensor does not limit the machines capabilities, as a workpiece mounted dynamometer does. To demonstrate capabilities of the technique for round coated and uncoated ceramic tooling, six tool wear life tests were conducted under various conditions. The indirect method discussed herein successfully tracks the tool’s wear, even with the occurrence of minor chipping, and is shown to be sensitive enough to provide sufficient time to replace the insert prior to damage of the machine tool, cutter, and/or workpiece.

Experimental Introduction to Surface Roughness Parameters Measurement

2013 ◽  
Vol 759 ◽  
pp. 63-71 ◽  
Author(s):  
Daniel Teixidor ◽  
Guillem Quintana ◽  
Joaquim de Ciurana
Keyword(s):  
Surface Roughness ◽  
Engineering Students ◽  
End Milling ◽  
Experimental Methodology ◽  
Milling Operations ◽  
Texture Generation ◽  
Training Courses ◽  
Experimental Introduction ◽  
Machining Operations ◽  
Parameters Measurement

Surface roughness influences the performance of a finished part. In machining operations, the surface roughness generated is influenced by an enormous set of factors. In ball end milling operations, the geometric characteristics of the cut clearly affect the surface crests generated. This paper presents an experimental methodology that permits engineering students to identify and analyze the surface roughness. The methodology is applicable to training courses and surface texture generation as well.

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