Nowadays in die-cast manufacturing high speed milling are used to increase quality, accuracy and speed of material processing, also to reduce processing costs and save machining time. This paper is devoted for research of high-speed processing regimes impacts and their effect on the surface roughness quality of the machined material and 3D surface parameter values. This paper contains recommendations for die-cast manufacturers, deploying HSM, to improve machining process and obtain required surface quality. Analysis of variance methodology is used in this research. Research identify the most appropriate HSM regimes, that most important is chosen material type or material mechanical properties, influencing kurtosis of the scale-limited surface (Sku) and height of the bearing area ratio curve (Stp). Feed rate is most significant for texture aspect ratio (Str) and strategy type -influencing parameter of arithmetic mean surface height (Sa) and valley fluid retention index (Svi).
This article presents the development and design of a laser cladding machine for in-situ marine diesel engine crankshaft repairs. The described technology and device is designed to perform crankpin journal renovation operations directly in the engine housing, without removing the crankshaft from the engine. This paper outlines the novel, in-situ concept of applying laser cladding to marine crankshaft repairs. Laser cladding technology is described along with the state of laser cladding implementation in modern production engineering. The principal design of the in-situ laser cladding machine is presented and accompanied by a detailed description of the in-situ laser cladding machine construction. Arguments for the selection of appropriate laser nozzles are provided based on state-of-the-art technology. Technological challenges deriving from the industrial use of the laser equipment are outlined. The proposed device and method satisfy ship-board crankshaft surface renovation needs and open up an entirely new dimension for the industrial application of laser cladding technologies. This technology provides clear economic benefits and many technological advantages.
High-speed milling is an effective machining method extensively used in modern material processing. This machining method offers increased efficiency, quality and accuracy of the machined surface as well as considerably reducing overall production costs and machining time. This paper outlines comprehensive research into the impact of the technological strategy and processed materials on carefully selected 3D surface roughness parameters. This research provides manufacturers who use high-speed milling with recommendations on how to better obtain the desired surface roughness parameters. More specifically, it covers multifactorial analysis of the following factors: feed rate, manufacturing strategy, overlap and material influences on the most characteristic 3D surface parameters. The results are based on ANOVA – analysis of variance, where differences between groups of means are analysed using a range of statistical models.
Subsequent analysis and respective conclusions identify the most significant factors as being the material and high-speed milling manufacturing strategy. Analytically justified recommendations for manufacturers regarding the preferred high-speed milling strategies are provided.
The research concluded that the values of the selected 3D surface roughness parameters in high-speed milling depend significantly on the type of material being machined, milling mode and cutting tool overlap as well as feed. In particular, Sa - the arithmetic mean height, is highly sensitive to the milling mode.
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