A case for aggressive drilling of aluminum

Hamade, Ramsey F.; Ismail, F.

doi:10.1016/j.jmatprotec.2004.07.099

Cited by 39 publications

(18 citation statements)

References 46 publications

(46 reference statements)

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“…The stress at the secondary shear plane are usually 30% less than those of the primary shear [30] [31]. Overall increase in the cutting speed will reduce cutting forces but in some cases high speed cutting causes excessive increase in the deformation rates that may result in increased machining forces [32] [33]. High speed machining of alloys containing hard particles will result in elevated cutting forces due to excessive flank wear occurring to the cutting tool [34].…”

Section: Cutting Forces Generated and Factors Affecting Themmentioning

confidence: 99%

Milling parameters of Al-Cu and Al-Si cast alloys

Mofidi

Zedan

Samuel

et al. 2019

Int J Adv Manuf Technol

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The present study was carried out to study the machinability i.e. milling characteristics of an Al-6%Cu-0.7%Si alloy (in the as-cast, T5 and T7 aging conditions) and compare these characteristics to those of well-defined B319.0 (as-cast, T7-treated) and A356.0 (as-cast, T6-treated) alloys. Wet milling was carried out on 15 blocks prepared from each alloy using new carbide inserts for about 120m machining distance. Thirty-five blocks (12 in x 7 in x 1.5 in) were employed. The milling was carried out using a CNC Huron KX Five 5axis high speed machine. The experiment comprised the CNC machine, the blocks to be machined, a table dynamometer with piezoelectric sensors that are responsible for detecting and measuring the cutting forces, a signal amplifier and an A/D converting unit. New and dull cutting inserts were used for each alloy group. Thirteen layers of material were removed from each block, where each layer consisted of 10 paths, and the depth of cut was 1.35 mm. The results employing new inserts showed that the cutting forces for Al-Cu based alloys were not affected by the applied heat treatment. The presence of Cu in the B319.0 alloy neutralized to some extent the harmful effect of the hard Si particles. Maximum cutting forces were obtained from machining the T6-treated A356.0 alloy, due to the presence of a high density of hard eutectic silicon particles (approximately 41495 particles∕mm 2) in addition to a dense precipitation of ultra-fine Mg 2 Si particles. Thus, the 6% Cu in the Al-Cu based alloy may be considered to act as a self-lubricant, leading to much smoother finishing surfaces compared to those exhibited by B319.0 and A356.0 alloys. Similar observations were reported on the wearing of the drilling tools. In addition, after covering 120m machining distance, tiny burrs were found adhered to the outer edges of the block workpiece, whereas the burr in the case of A356.0 alloy was separated from the block.

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Section: Cutting Forces Generated and Factors Affecting Themmentioning

confidence: 99%

Milling parameters of Al-Cu and Al-Si cast alloys

Mofidi

Zedan

Samuel

et al. 2019

Int J Adv Manuf Technol

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“…Weaknesses of this process application for the production of channels are the following: i) Requirement of extra holes and pipe plugs [20]; ii) Challenge to drill long holes and/or of small diameter; iii) Does not enable a conformal cooling strategy; and iv) Production of circular shapes only (which have the smallest surface to volume ratio, for the same volume of channel). The drilling and milling [21] are probably the most common techniques applied in the production of small-scale or small batch production of panels for thermal management. The milling creates open channels with different shapes and depths and a smooth surface finish.…”

Section: Introductionmentioning

confidence: 99%

Thermal Efficiency and Material Properties of Friction Stir Channelling Applied to Aluminium Alloy AA5083

et al. 2019

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The Friction Stir Channelling (FSC) is a novel advanced solution for producing internal closed channels along any desired path with a constant or continuously modified shape along the path in a single manufacturing step. The channels are formed by continuous extraction of part of the stirred processed material into external flash. In this work, the performance of channels with the same shape and dimensions but produced by FSC and milling respectively, are compared using an experimental calorimeter setup with a focus on the influence of the geometrical features of the channels on the thermal efficiency. The investigation is implemented in a plate of AA5083-H111, with a thickness of 10 mm. The material properties of the channels produced by FSC are investigated with a microhardness field and optical microscopic analysis, assessing the thermomechanically processed and heat affected zones. The mechanical resistance of the channels produced by FSC is evaluated with an application of internal pressure up to 380 bar. The results show that the FSC enhanced the heat transfer by about 45 % compared with smoother milled channels. The optical microscopy shows evidence of a good consolidation of the solid state joining mechanisms activated during the FSC, with a small reduction of the hardness around the channel in the stirred zone and heat affected zone, being assisted by a harder top region at the ceiling of the channel.

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“…Machining of aluminum alloys is an important production activity in the automotive and aeronautical industries, due to the large application of aluminum in the transportation sector [1,2]. This is because of its great versatility in terms of properties and, among them, its low density and high strength to weight ratio stand out, which makes aluminum, after iron, the materials most used in the manufacture of parts [3][4][5]. According to Davies et al [6] the automotive industry is continuously developing technologies to reduce vehicle costs and weights; and with that, reducing the environmental impact with energy consumption.…”

Section: Introductionmentioning

confidence: 99%

“…This work is justified due to the ability of the analysis of variance and factorial analysis to investigate the joint influence (simultaneous) of the mechanical strength and cutting conditions (input variables) on the cutting temperature. In machining, few researches have been conducted in this way, since most of them study the influences of the main input variable isolated and rarely considering their interactions in the way conducted here; for instance, the influence of the cutting speed or the feed rate on the cutting forces; the effect of the hardness on the cutting temperature [4,8,9]. This greatly limits the discussion about how interactions between inputs variables can affect the responses.…”

Section: Introductionmentioning

confidence: 99%

Temperature in Machining of Aluminum Alloys

Santos¹,

Machado²,

Barrozo³

2018

Temperature Sensing

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The objective this work is to study the effect of the mechanical property of the workpiece (tensile strength) and cutting conditions (cutting speed, feed rate, depth of cut and lubricooling system) over the cutting temperature in turning of aluminum alloys. A 2 k factorial planning was used to determine the machining test conditions. ANOVA and Regression Analysis of the results were performed. The main contribution of this work lies on its efficiency of describing the behavior of the cutting temperature as a function of the input variables. The results found in the present work have considered the interactions of the input variables, describing the cutting temperature in a complete way, not seen previously in the literature.

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A case for aggressive drilling of aluminum

Cited by 39 publications

References 46 publications

Milling parameters of Al-Cu and Al-Si cast alloys

Milling parameters of Al-Cu and Al-Si cast alloys

Thermal Efficiency and Material Properties of Friction Stir Channelling Applied to Aluminium Alloy AA5083

Temperature in Machining of Aluminum Alloys

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