scholarly journals Efficiency and Sustainability Analysis of the Repair and Maintenance Operations of UNS M11917 Magnesium Alloy Parts of the Aeronautical Industry Made by Intermittent Facing

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1035
Author(s):  
Jacobo Fernández ◽  
Eva María Rubio ◽  
Diego Carou ◽  
Raquel María Lorente-Pedreille
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Magnesium Alloy ◽  
Environmental Impact ◽  
Operating Time ◽  
Cutting Parameters ◽  
Sustainability Analysis ◽  
Aeronautical Industry ◽  
Machining Operations ◽  
Cooling And Lubrication

This paper analyzes the efficiency and sustainability of facing operations that are required within maintenance operations in the aeronautical industry. Due to the elevated cost and environmental impact of such processes, reducing the operating time while repairing parts is required. In this work, an experimental study of intermittent facing carried out on a magnesium alloy rod was developed. The experiment resembles real repair and maintenance machining operations, where an intermittent facing represents a more realistic scenario and where the results obtained in continuous turning studies are not always applicable. The work was performed with different cooling and lubrication systems and various cutting conditions, also considering the size of the interruption to analyze their impact in the surface roughness. To this end, surface finished in different measuring zones was studied. The aims of the study are to get a better understanding of the intermittent facing process in magnesium alloys typically employed in aeronautical applications and find the most efficient cutting parameters to obtain an improved surface under the safest and most environmentally respectful conditions.

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Shahfizal Ruslan ◽  
Kamal Othman ◽  
Jaharah A.Ghani ◽  
Mohd Shahir Kassim ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Polishing Process ◽  
High Speed Cutting ◽  
Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

scholarly journals Investigate the Effect of Cutting Parameters on Surface Roughness When Milling X12m Steel

2021 ◽  
pp. 258-263
Author(s):  
Do Thi Kim Lien ◽  
Nguyen Dinh Man ◽  
Phung Tran Dinh
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Negligible Effect ◽  
Depth Of Cut ◽  
The Relationship

In this paper, an experimental study on the effect of cutting parameters on surface roughness was conducted when milling X12M steel. The cutting tool used in this study is a face milling cutter. The material that is used to make the insert is the hard alloy T15K6. The cutting parameters covered in this study include the cutting speed, the feed rate and depth of cut. The experiments are performed in the form of a rotating center composite design. The analysis shows that for both Ra and Rz: (1) the feed rate has the greatest influence on the surface roughness while the depth of cut, the cutting speed has a negligible effect on the surface roughness. (2) only the interaction between the feed rate and the depth of the cut has a significant effect on both Ra and Rz while the interaction between the cutting speed and the feed rate, the interaction between the cutting speed and the depth of cut have a negligible effect on surface roughness. A regression equation showing the relationship between Ra, Rz, and cutting parameters has also been built in this study.

Influence of Cutting Parameters on the Surface Quality of Round Parts Made from AZ61 Magnesium Alloy and Machined by Turning

2013 ◽  
Vol 837 ◽  
pp. 128-134 ◽  
Author(s):  
Gheorghe Mustea ◽  
Gheorghe Brabie
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Magnesium Alloy ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Az61 Magnesium Alloy ◽  
Machined Surfaces

The use of magnesium alloys in construction of different components of the mechanical systems (such: cars, aerospace vehicles, medical equipment etc.) is very efficient not only because it leads to reduction of the systems weight but also because it leads to reduction or elimination of the environment polluting and to reduction of the energy consumption. Generally, the main factors that influence the quality of the machined surfaces are as follows: cutting parameters, material properties, geometry of the tools, cooling liquids and lubricants, physical and mechanical properties of the subsurface layers etc. Among the above mentioned factors, cutting parameters are the factors that strongly influence the quality of the machined surfaces. The present paper analysis the results of the experimental investigation performed to determine the influence of cutting parameters (cutting speed, feed rate and cutting depth) on the surface quality machined by turning the AZ61 magnesium alloy. The main characteristics of the machined surface quality analyzed in experimental investigation were the surface roughness and hardness. The main conclusions resulted from the results analysis were as follows: the decrease of the feed rate led to surface roughness decrease and hardness increase; the increase of the cutting speed also led to an improved surface quality.

Experimental Study on Spray Cutting Ni-Based Superalloy

2012 ◽  
Vol 723 ◽  
pp. 317-321
Author(s):  
Yu Wang ◽  
Yuan Sheng Zhai ◽  
Fu Gang Yan ◽  
Xian Li Liu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Production Mode ◽  
Effective Reduction ◽  
Reasonable Choice ◽  
Base Superalloy

In this paper, the effect of cutting parameters on cutting force, cutting temperature and surface roughness on cutting force, cutting temperature and surface roughness are experimentally studied in spray cutting GH4169 Ni-base superalloy used carbide cutting tools. The results showed that reasonable choice of cutting parameters can effective reduction of cutting force and cutting temperature, and improve the machining surface roughness. Thus realizing clean production mode.

Surface Roughness Predictive Model of UNS A97075 Aluminum Pieces Obtained by Dry Turning Tests Based on the Cutting Forces

2012 ◽  
Vol 217-219 ◽  
pp. 1628-1635 ◽  
Author(s):  
Beatriz De Agustina ◽  
Eva María Rubio ◽  
Miguel Ángel Sebastián
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Predictive Model ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Turning ◽  
Frequency Domains ◽  
Range Of Values ◽  
Roughness Measurements

The present work shows an experimental study for a first approach of a surface roughness predictive model of UNS A97075 aluminum pieces obtained by dry turning tests based on the cutting forces. In a first step, a design of experiments (DOE) 25 was employed to analyse the influence of the cutting parameters and type of tool on the surface roughness with the objective to find out a combination of cutting conditions that allow obtaining a range of values of surfaces roughness according to the aeronautical specifications requierements. The factors considered for this design were the feed rate, spindle speed, depth of cut, type of tool (nose radious) and machined length (zone of the workpiece where the surface roughness measurements are taken). The obtained data was analysed by means of the analysis of variance (ANOVA) method. And secondly, with the previous selected conditions selected it was developed by multiple regression a model to predict the surface roughness by measuring the cutting forces generated during the dry turning tests of aluminum alloy UNS A97075 pieces. The predictive model of surface roughness obtained includes statistical values calculated from the forces sygnal in time and frequency domains.

Experimental Study on Precision Milling of High Volume Fraction SiCP/Al Composites with PCD End Mills

2013 ◽  
Vol 770 ◽  
pp. 100-105 ◽  
Author(s):  
Qi Wu ◽  
Liang Li ◽  
Rong Bian ◽  
Zhen Yu Shi ◽  
Ning He
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Tool Wear ◽  
Volume Fraction ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
Experimental Result ◽  
Machined Surface ◽  
End Mills

This paper presents an experimental study on precision milling of high volume fraction SiCP/Al composites with single flute polycrystalline diamond (PCD) end mills. Based on a series of tests, the present study is focused on surface roughness of machined surface and tool wear of single flute PCD end mills. The effect of cutting parameters such as feed per tooth (fz) and depth of cut (ap) on the machined surface roughness (Ra) was investigated. Tool wear was also inspected and analyzed by Scanning Electron Microscope (SEM). According to the results of experiment, there is a layer of aluminum covered on the machined surface. This layer of aluminum can improve the machined surface quality. Through the comparsion of surface roughness in different cutting parameters, it can decrease surface roughness (Ra) by means of using very small cutting parameters. Flank wear and chipping are two main kinds of tool wear. The observed wear mechanism of PCD tools is abrasive wear and adhesive wear. The purpose of this study is to provide an experimental result for further investigation on milling of high volume fraction SiCP/Al composites.

scholarly journals Optimization of Cutting Speed and Feed Rate on Surface Roughness and Vibration using Taguchi Method: A Review

2020 ◽  
Vol 1 (2) ◽  
pp. 43
Author(s):  
Mohammad Ilham ◽  
Suparjon Suparjon ◽  
Yudistira Sanjiwani
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Machine Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Dominant Factor ◽  
Workpiece Surface ◽  
Material Hardness ◽  
Machining Operations

<span lang="EN-ID">The result of a turning process is strongly influenced by the process parameters that could result in the product to be unacceptable. The cutting parameters may be determined according to the material hardness and roughness of the workpiece surface. The purpose of this paper is to investigate the effects of cutting speed and feed rate on surface roughness and vibration. In Taguchi method, the number of experiments is reduced by orthogonal arrays while  the effects of uncontrollable factors are also also reduced. The Taguchi method is used to reduce track, experimental time and production cost. Simple and precise are the most benefits of this method. Unstable vibrations in machining operations, known as chats, can cause damage to tools, workpieces, and machine tools. Cutting force is found to be the most dominant factor affecting surface roughness.</span>

Analysis of Surface Roughness for High Speed Milling of a Magnesium Alloy Part

2013 ◽  
Vol 837 ◽  
pp. 33-38 ◽  
Author(s):  
Bogdan Chirita ◽  
Nicolae Catalin Tampu
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Surface Quality ◽  
Product Life Cycle ◽  
High Speed ◽  
Fatigue Behavior ◽  
Cutting Parameters ◽  
Good Surface ◽  
Cooling Conditions ◽  
Higher Temperature

Surface roughness represents an important characteristic in the appreciation of a part quality. A good surface quality can enhance corrosion resistance and fatigue behavior throughout product life cycle. Magnesium alloys have gained in the recent years a larger use due to an excellent ratio between mechanical strength and weight. Cooling conditions are particularly important when machining magnesium. The chips are flammable and highly reactive with water based fluids. Higher temperature favors also the formation [email protected] built-up edge and worsens surface quality. The present paper analyses the influence of cooling conditions and cutting parameters on surface roughness of the parts made of magnesium alloy. Using design of experiments technique, a series of experiments were organized and based on that a connection between surface quality and cutting conditions was established.

Investigation of the shearing length in the orthogonal turning of a steel AISI 1050

2020 ◽  
Vol 62 (8) ◽  
pp. 827-834
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Steel Material ◽  
Lathe Machine ◽  
Steel Aisi ◽  
Natural Mechanism ◽  
Impossible Task ◽  
Machining Operations

Abstract Vibration amplitudes in machining operations have a deteriorating influence on the outcomes of the processes. Moreover, eradicating them is an impossible task due to the natural mechanism of cutting metals. However, by selecting the optimum cutting parameters, the destructive effects of vibration amplitudes may be diminished to acceptable levels. In the present paper, AISI 1050 steel material was machined, employing carbide inserts and a CNC lathe machine. Cutting tool approaching angles were selected between -5° and 45°, feed rates from 0.1 mm × rev-1 to 0.5 mm × rev-1, cutting depths between 0.5 mm and 2.25 mm, and accordingly CSR values between 1 and 15. The effect of the selected parameters on the chip compression factor (CCF), shearing length feed (SLF), shearing length (SLA), surface roughness, and chip morphology was investigated. Moreover, the effect of CCF, SLF, and SLA on surface roughness, vibration amplitudes, and chip morphology was analyzed as well. It was found that the most influential parameter on shearing length was cutting depth while the feed rate was on the surface roughness. The optimum CCF values were between 1.7 and 2.3, SLF smaller than 1, and SLA around 5. Furthermore, it was shown that the optimum CSR values were 10 and 15, and cutting tool approaching angles 30° and 45°, according to the chip morphology criterion.

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