Experimental Study of Factors Affecting the 7075 Aluminum Alloy Thin-walled Parts Milling Force

2016 ◽  
Vol 10 (8) ◽  
pp. 29-34
Author(s):  
Fengyun Yu ◽  
Lin Wu ◽  
Yunliang Fu ◽  
Yanyan Guo ◽  
Can Zhao ◽  
...  
Keyword(s):  
Experimental Study ◽  
Aluminum Alloy ◽  
7075 Aluminum Alloy ◽  
Milling Force ◽  
Factors Affecting ◽  
Thin Walled

Optimization of Milling Process for Aluminum Alloy Frame Part Based on Milling Force Analysis

2014 ◽  
Vol 575 ◽  
pp. 437-441
Author(s):  
Yi Shu Hao ◽  
Guo Qing Tang ◽  
Meng Zhang
Keyword(s):  
Aluminum Alloy ◽  
Selection Method ◽  
Milling Process ◽  
Parameter Selection ◽  
Force Analysis ◽  
Milling Force ◽  
Finite Element Software ◽  
Milling Parameters ◽  
Machining Errors ◽  
Thin Walled

In order to solve the problem of size guarantee related to thin-walled structure in traditional milling parameter selection, specific aluminum alloy frame part contains curved surface and thin-walled structure is studied. Numerical analysis is used in milling parameter selection method. Machining errors are calculated and checked based on milling force analysis. The milling process is simulated using finite element software. And aluminum alloy frame part processing is optimized from the angle of milling parameters according to the simulation results. Optimized milling parameters scheme is acquired, the results show that both machining precision and efficiency of the frame part are improved.

Experimental study on cold forming process of 7075 aluminum alloy in W temper

2022 ◽  
Vol 37 ◽  
pp. 11-18
Author(s):  
Junying Min ◽  
Fangli Xie ◽  
Yi Liu ◽  
Zeran Hou ◽  
Jiaxin Lu ◽  
...  
Keyword(s):  
Experimental Study ◽  
Aluminum Alloy ◽  
7075 Aluminum Alloy ◽  
Forming Process ◽  
Cold Forming

Study on Spinning Process of a Thin-Walled Aluminum Alloy Vessel Head With Small Ratio of Thickness to Diameter

2010 ◽  
Vol 132 (1) ◽  
Author(s):  
Yanqiu Zhang ◽  
Debin Shan ◽  
Wenchen Xu ◽  
Yan Lv
Keyword(s):  
Aluminum Alloy ◽  
Feed Ratio ◽  
Small Range ◽  
Factors Affecting ◽  
Small Ratio ◽  
Spinning Process ◽  
Conventional Spinning ◽  
Thin Walled ◽  
Line Trajectory ◽  
Blank Size

The thin-walled vessel head with the ratio of thickness to diameter less than 3‰ has long been considered to be difficult to be spun because wrinkling is very likely to occur during the thin-walled vessel head spinning process when the thickness is far smaller than the diameter. Based on process experiments and finite element method, the spinning failure of thin-walled vessel head with a small ratio of thickness to diameter is analyzed in the present research. The mechanism of wrinkling is identified and some effective solutions are discussed to prevent the failure. The results show that the feed ratio, the blank geometry, and the roller trajectory are the main factors influencing the spinning qualities. In the shear spinning, the feasible roller feed ratio is found to be within a very small range because of the thin thickness of blanks. Wrinkling will occur if the feed ratio is slightly outside the operation range. Bending the edge of blank or enlarging the blank size can effectively prevent wrinkling at a larger feed ratio, which would increase the operation range of roller feed ratio. Due to the fact that the conventional spinning is a process of multiple passes, there are many factors affecting the forming quality of thin-walled aluminum alloy vessel head. Wrinkling is likely to happen by the influence of roller trajectory in the first pass due to the fact that the thickness of blank is far smaller than the diameter. The straight-line trajectory is the worst trajectory under which wrinkling is most likely to occur.

scholarly journals Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Zhenjing Duan ◽  
Changhe Li ◽  
Wenfeng Ding ◽  
Yanbin Zhang ◽  
Min Yang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Research Progress ◽  
Machining Accuracy ◽  
Force Model ◽  
Milling Force ◽  
Thin Walled ◽  
Milling Forces ◽  
Milling Force Model

AbstractAluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In view of these problems, the future work direction is proposed in the following four aspects: (1) high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth, which easily produces high residual stress. The residual stress should be analyzed under this particular condition. (2) Multiple factors (e.g., eccentric swing milling parameters, lubrication conditions, tools, tool and workpiece deformation, and size effect) should be considered comprehensively when modeling instantaneous milling forces, especially for micro milling and complex surface machining. (3) The database of milling force model, including the corresponding workpiece materials, working condition, cutting tools (geometric figures and coatings), and other parameters, should be established. (4) The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling. (5) The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication (mql) and nanofluid mql should be predicted.

scholarly journals Experimental Analysis and Prediction Model of Milling-Induced Residual Stress of Aeronautical Aluminum Alloys

2021 ◽  
Vol 11 (13) ◽  
pp. 5881
Author(s):  
Shouhua Yi ◽  
Yunxin Wu ◽  
Hai Gong ◽  
Chenxi Peng ◽  
Yongbiao He
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Prediction Model ◽  
End Milling ◽  
Orthogonal Experiment ◽  
7075 Aluminum Alloy ◽  
Side Milling ◽  
Milling Parameters ◽  
Thin Walled ◽  
Machining Deformation Prediction

Aeronautical thin-walled frame workpieces are usually obtained by milling aluminum alloy plates. The residual stress within the workpiece has a significant influence on the deformation due to the relatively low rigidity of the workpiece. To accurately predict the milling-induced residual stress, this paper describes an orthogonal experiment for milling 7075 aluminum alloy plates. The milling-induced residual stress at different surface depths of the workpiece, without initial stress, is obtained. The influence of the milling parameters on the residual stress is revealed. The parameters include milling speed, feed per tooth, milling width, and cutting depth. The experimental results show that the residual stress depth in the workpiece surface is within 0.12 mm, and the residual stress depth of the end milling is slightly greater than that of the side milling. The calculation models of residual stress and milling parameters for two milling methods are formulated based on regression analysis, and the sensitivity coefficients of parameters to residual stress are calculated. The residual stress prediction model for milling 7075 aluminum alloy plates is proposed based on a back-propagation neural network and genetic algorithm. The findings suggest that the proposed model has a high accuracy, and the prediction error is between 0–14 MPa. It provides basic data for machining deformation prediction of aluminum alloy thin-walled workpieces, which has significant application potential.

scholarly journals Effects of TVSR process on the dimensional stability and residual stress of 7075 aluminum alloy parts

2021 ◽  
Vol 60 (1) ◽  
pp. 631-642
Author(s):  
Yan Xu ◽  
Zhongjun Shi ◽  
Bianhong Li ◽  
Zhang Zhang
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Dimensional Stability ◽  
Stress Relief ◽  
Bending Stiffness ◽  
Machining Process ◽  
7075 Aluminum Alloy ◽  
Maximum Deformation ◽  
Equivalent Bending Stiffness ◽  
Thin Walled

Abstract Residual stress generated during the blank forming and machining process significantly influences the dimensional stability of the mechanical parts. The equivalent bending stiffness and thermal vibration stress relief (TVSR) are two factors that affect the deformation of thin-walled workpiece. To increase the machining accuracy, on the one hand, increase the equivalent bending stiffness in manufacturing, and on the other hand, usually conduct the stress relief process to reduce the residual stress in manufacturing. In the present study, morphology optimization and TVSR process are conducted on a thin-walled part Specimen B of 7075 aluminum alloy to control the residual stress and machining deformation before finish machining. As a contrast, Specimen A is machined in one step. The deformations vary with time of Specimen A and B are measured. The corresponding finite element model is built to further study the stress and distortion during the machining process. Results showed that (1) deformation decreased with the increase of equivalent bending stiffness, compared with Specimen A, the maximum deformation of Specimen B decreased by 58.28%. (2) The final maximum deformation of Specimen B can be reduced by 38.33% by topology reinforcement to improve the equivalent stiffness and TVSR to reduce the residual stress.

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