Research on the Properties of Milling and the Process Parameters Optimization for Aluminum-Alloy Thin-Walled Parts

2010 ◽  
Vol 44-47 ◽  
pp. 2842-2846
Author(s):  
Xiao Hui Jiang ◽  
Bei Zhi Li ◽  
Jian Guo Yang ◽  
He Long Wu
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Low Cost ◽  
Parameters Optimization ◽  
Milling Parameters ◽  
Milling Simulation ◽  
Optimization Of Process Parameters ◽  
Thin Walled ◽  
Parts Manufacturing

In this paper, with the milling processing of aluminum-alloy thin-walled parts as the research object, using software AdvantEdge, a milling simulation model is developed to study milling parameters affect on the cutting force, heat and catenation. It is found that by adjusting the ratio of milling parameters, the effects of cutting forces and heat can turn to the favorable direction of workpiece. In addition, we combine numerical simulation with experiments to explore the law of optimization of process parameters. It is discovered that the method of improving the milling speed and reducing the cutting depth properly can ensure the milling efficiency and the quality of the workpiece, providing a scientific insight for achieving high-quality, low-cost and efficient thin-walled parts manufacturing.

Research on Finite Element Simulation and Parameters Optimization of Milling 7050-T7451 Aluminum Alloy Thin-walled Parts

2020 ◽  
Vol 14 ◽  
Author(s):  
Song Yang ◽  
Tie Yin ◽  
Feiyue Wang
Keyword(s):  
Aluminum Alloy ◽  
Complex Structure ◽  
Parameters Optimization ◽  
Thin Wall ◽  
Machining Parameters ◽  
Milling Parameters ◽  
Machining Deformation ◽  
Milling Temperature ◽  
Thin Walled ◽  
Milling Forces

Background: Thin-walled parts of aluminum alloy are easy to occur machining deformation duo to the characteristics of thin wall, low rigidity, and complex structure. Objective: To reduce and control the machining deformation, it is necessary to select reasonable machining parameters. Method: The influence of milling parameters on the milling forces, milling temperature, and machining deformation was analyzed through the established model based on ABAQUS. Then, the corresponding empirical formula was obtained by MATLAB, and parameters optimization was carried out as well. Besides, a lot of patents on machining thin-walled parts were studied. Results: The results shown that the prediction error of milling forces is about 15%, and 20% of milling temperature. In this case, the optimized milling parameters are as follows: ap=1 mm, ae=0.1 mm, n=12 000 r/min, and f=400 mm/min. It is of great significance to reduce the machining deformation and improve the machining quality of thin-walled parts.

scholarly journals Study on the Influence of Surface Temperature Field of Aluminum Alloy Etched by Laser Water Jet Composite Machining

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3206
Author(s):  
Xuehui Chen ◽  
Xin Xu ◽  
Wei Liu ◽  
Lei Huang ◽  
Hao Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Temperature Field ◽  
Surface Temperature ◽  
Process Parameters ◽  
Water Jet ◽  
Laser Machining ◽  
Material Surface ◽  
Laser Etching ◽  
Surface Temperature Field

This paper studies the compound effect of liquid medium and laser on the workpiece and analyses the law of material surface temperature change during the processing. Taking 7075-T6 aluminum alloy as the research object, the surface temperature field of aluminum alloy processed using water-jet-assisted laser machining under different process parameters was simulated using finite element software. In addition, the temperature field of the material surface was detected in real-time using the self-built water-jet-assisted laser machining temperature field detection system, and the processing results were observed and verified using an optical microscope, scanning electron microscope, and energy spectrum analyzer. The results show that when the water jet inflow angle is 45°, the heat-affected area of the material surface is the smallest, and the cooling effect of the temperature field of the material surface is better. Considering the liquidus melting point of 7075 aluminum alloys, it is concluded that the processing effect is better when the water jet velocity is 14 m·s−1, the laser power is 100 W, and the laser scanning speed is 1.2 mm·s−1. At this time, the quality of the tank is relatively good, there are no cracks in the bottom of the tank, and there is less slag accumulation. Compared with anhydrous laser etching, water-jet-assisted laser etching can reduce the problems of micro-cracks, molten slag, and the formation of a recast layer in laser etching and improve the quality of the workpiece, and the composition of the bottom slag does not change. This study provides theoretical guidance and application support for the selection and optimization of process parameters for water-jet-assisted laser etching of aluminum alloy and further enriches the heat transfer mechanism of multi-field coupling in the process of water-jet-assisted laser machining.

scholarly journals Effect of process parameters on longitudinal weld seam quality of aluminum alloy profile for an automobile fuel tank protector

2020 ◽  
Vol 50 ◽  
pp. 159-167
Author(s):  
Wenlin Chen ◽  
Chen Xu ◽  
Penglin Pan ◽  
Xiangming Ruan ◽  
Hongxuan Ji
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Weld Seam ◽  
Fuel Tank ◽  
Longitudinal Weld Seam

scholarly journals Optimization of process parameters in the RF-DC plasma N2-H2 for AISI420 molds and dies

2019 ◽  
Author(s):  
Hengky Herdianto ◽  
Dionisius Johanes Djoko Herry Santjojo ◽  
Masruroh
Keyword(s):  
Process Parameters ◽  
Substrate Surface ◽  
Xrd Analysis ◽  
Iron Nitrides ◽  
Dc Plasma ◽  
Precision Forging ◽  
Optimization Of Process Parameters ◽  
Dc Bias ◽  
Substrate Surfaces

The RF-DC plasma N2-H2 was used to make precise AISI420 molds and dies have complex textured geometry. The quality of the molds and dies directly affect the quality of the produced parts. The excellent examples of molds were used for injection molding lenses and dies used for the precision forging of automotive drive train components. In this study, a temperature, DC bias, and duration as process parameters of the RF-DC plasma N2-H2 have been optimized for molds and dies fabrication. The mask-less micro-patterned method was utilized to draw the initial 2D micro patterns directly onto the AISI420 substrate surface. The unprinted substrate surfaces were selectively nitrided by the RF-DC plasma N2-H2 at 673 K for 5400 s by 70 Pa with hollow cathode device. Energy Dispersive X-ray was utilized to describe the nitrogen content distribution at the vicinity of the border between the unprinted surfaces. This exclusive nitrogen mapping proves that only the unprinted parts of the substrate have high content nitrogen solutes. XRD analysis was performed to investigate whether the iron nitrides were precipitated by RF-DC plasma N2-H2 in the AISI420.

Design Milling Parameters Optimization System Based on Thin-Walled Parts

2011 ◽  
Vol 189-193 ◽  
pp. 2482-2485
Author(s):  
Xin Hua Mao ◽  
Zhi Gang Hu ◽  
Ting Ting Huang
Keyword(s):  
Structural Features ◽  
Parameters Optimization ◽  
Processing Conditions ◽  
Milling Force ◽  
Optimization System ◽  
Milling Parameters ◽  
Low Stiffness ◽  
Thin Walled

Because of its low stiffness and intensity structural features, thin-walled parts affected by milling force, easily produce deformation and vibration among processing. In this paper, by optimizing milling parameters, it can be realized to control the size of the dynamic milling force and the milling state. Then it reaches the purpose to decrease workpiece deformation, and makes processing conditions maintain a stable. It not only reduces deformation caused by the vibration, but also makes thin-walled parts errors meet the tolerance requirements.

scholarly journals Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

2019 ◽  
Vol 224 ◽  
pp. 05009
Author(s):  
Xiangjing Kong ◽  
Zishan Ding ◽  
Lijun Xu ◽  
Lijian Zhu ◽  
Jian Zhang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Curved Surface ◽  
Surface Residual Stress ◽  
Milling Parameters ◽  
Aerospace Research ◽  
Research Areas ◽  
Milling Simulation ◽  
Reasonable Range ◽  
Thin Walled ◽  
And Control

With the increasing application of curved thin-walled parts, the evaluation and control of curved surface residual stress in milling are becoming increasingly demanding. However, effects of milling parameters on distribution of residual stress remains a major challenge in the present aerospace research areas. In this paper, , impacts of milling parameters on curved surface residual stress have been investigated in a series of residual stress experiments and simulations. It is found that the residual stress can be lowered by increasing milling speed and tool radius within a reasonable range. The superposition of curved surface residual stress under two machining conditions have been analyzed using the milling simulation model. It has been found that the curved surface residual stress induced by the subsequent cutting will be superimposed on the curved surface residual stress induced by the previous cutting and that the superposition rates of residual stress induced by up milling are larger than down milling.

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