scholarly journals The influence of the cooling method on high performance cutting of the AlZn5.5MgCu alloy

Mechanik ◽  
2018 ◽  
Vol 91 (10) ◽  
pp. 883-885
Author(s):  
Jan Burek ◽  
Marcin Płodzień ◽  
Łukasz Żyłka
Keyword(s):  
Aluminum Alloy ◽  
Cutting Forces ◽  
Vibration Amplitude ◽  
High Performance ◽  
Cooling Method ◽  
Relief Surface

The research of the high performance cutting of the aviation aluminum alloy was conducted. Four methods of the cooling delivery: flood, internal, on rake surface, on the relief surface, were applied. The influence of the cooling method on the cutting forces component and vibration amplitude was presented.

A Study of High-Performance Drills in the Drilling of Aluminum Alloy and Titanium Alloy

2013 ◽  
Vol 589-590 ◽  
pp. 163-167 ◽  
Author(s):  
Kun Xian Qiu ◽  
Sheng Qin ◽  
Chun Xin Ge ◽  
Ming Chen
Keyword(s):  
Titanium Alloy ◽  
Aluminum Alloy ◽  
Cutting Forces ◽  
High Performance ◽  
Thrust Force

Both aluminum alloy and titanium alloy have been widely used in aerospace, aviation, military and automotive industries. This research presents a study of modified drills for drilling aluminum alloy and titanium alloy. The modified drills can be expected to reduce the cutting forces and torque. A set of experiment was carried on to investigate the performance of the modified drills. A method to quantitative assess of the reduction of the thrust force and torque was given below, and the calculation shows that the modified drills can reduce the thrust force and the torque by as high as 21.16% and 90.48%, respectively, as compared to the conventional drills under the same conditions.

scholarly journals The influence of the cutter edge contour line on the cutting forces in the high performance cutting of AlZn5.5MgCu aluminum alloy

Mechanik ◽  
2015 ◽  
pp. 724/275-724/283
Author(s):  
Jan Burek ◽  
Łukasz Żyłka ◽  
Marcin Płodzień ◽  
Michał Gdula
Keyword(s):  
Aluminum Alloy ◽  
Cutting Forces ◽  
High Performance ◽  
Contour Line

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

Numerical Investigation of Ultimate Strength of Stiffened Plates With Various Cross-Section Forms

2018 ◽  
Author(s):  
Huilong Ren ◽  
Yifu Liu ◽  
Chenfeng Li ◽  
Xin Zhang ◽  
Zhaonian Wu
Keyword(s):  
Aluminum Alloy ◽  
Ultimate Strength ◽  
Cross Section ◽  
High Performance ◽  
Lightweight Design ◽  
Offshore Structures ◽  
Stiffened Plates ◽  
Stiffened Plate ◽  
Element Analysis ◽  
Hull Structure

There is an increasing interest in the lightweight design of ship and offshore structures, more specifically, choosing aluminum alloys or other lightweight high-performance materials to build structure components and ship equipments. Due to its better mechanical properties and easy assembly nature, extruded aluminum alloy stiffened plates are widely used in hull structures. When the load on the hull reaches a certain level during sailing, partial or overall instability of stiffened plate makes significant contribution in an event of collapse of the hull structure. It is very necessary to investigate the ultimate strength of aluminum alloy stiffened plate to ensure the ultimate bearing capacity of large aluminum alloy hull structure. Most of studies of the ultimate strength of stiffened plates deal with stiffened plates with T–shaped stiffeners. Stiffeners of other shapes have seldom been explored. In this research, the ultimate strength of six different cross–section aluminum alloy stiffened plates and one steel stiffened plate was studied based on the non–linear finite element analysis (FEA). Taking into account stiffness, weight and other issues, the new cross–section aluminum stiffener has finally been concluded for replacing the original steel stiffener in upper deck of a warship.

Additively Manufactured Continuous Fibre-Reinforced Thermoplastics for Mechanisms Subjected to Predominant Inertial Load: A Case Study

2020 ◽  
Author(s):  
Luca Luzi ◽  
Giacomo Quercioli ◽  
Riccardo Pucci ◽  
Guido Bocchieri ◽  
Rocco Vertechy ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Topology Optimization ◽  
High Performance ◽  
Permanent Magnet Synchronous Motor ◽  
Three Dimensional ◽  
Direct Drive ◽  
Continuous Fibre ◽  
Mechanical Components ◽  
Reinforced Thermoplastics

Abstract In the last decade, the adoption of additive manufacturing technologies (AMT) (3D printing) has increased significantly in many fields of engineering, initially only for rapid prototyping and more recently also for the production of finished parts. With respect to the long-established material subtractive technologies (MST), AMT is capable to overcome several limitations related to the shape realization of high-performance mechanical components such as those conceived via topology optimization and generative design approaches. In the field of structures and mechanisms, a major advantage of AMT over MST is that, for the same loading and constraining conditions (including kinematic and overall encumbrance), it enables the realization of mechanical components with similar stiffness but smaller volume (thus smaller weight, density being equal). Recently, the potentialities of AMT have also been increased by the introduction of the fuse filament deposition modeling (FDM) of continuous fibre-reinforced thermoplastics (CFRT), which combines the ease of processing of plastic AMT with the strength and specific modulus of the printed components that are comparable to those attainable via metallic AMT. In this context, the present paper investigates the potentialities of FDM-CFRT for the realization of mechanisms subjected to predominant inertial loads such as those found in automated packaging machinery. As a case study a Stephenson six-bar linkage powered in direct drive by a permanent magnet synchronous motor is considered. Starting from an existing mechanism realized in aluminum alloy with traditional MST, a newer version to be realized with FDM-CFRT has been conceived by keeping the kinematics fixed and by redesigning the links via three-dimensional topology optimization. To provide a fair comparison with the more traditional design/manufacturing approach, size optimization of the original mechanism made in aluminum alloy has also been performed. Comparison of the two versions of the mechanism highlights the superior performances of the one manufactured via FDM-CFRT in terms of weight, motor torque requirements and motion precision.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

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