Analysis of chip fragmentation in AZ91HP alloy milling with respect to reducing the risk of chip ignition

Gziut, Olga; Kuczmaszewski, Józef; Zagórski, Ireneusz

doi:10.17531/ein.2016.1.10

Cited by 11 publications

(13 citation statements)

References 9 publications

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“…In a broader sense, the concept of process effectiveness means the best results (defined by specific quantities) obtained in the production process at the lowest costs possible. The effectiveness of manufacturing aircraft components, ensuring their high reliability, depends on a number of factors, e.g., the correct design of a product; the application of an appropriate production strategy; the use of tools with extended service life; the application of machining parameters ensuring the efficiency and at the same time high stability of the process; proper supervision of the process, and quick effective response to the loss of productivity, or the use of appropriate machine tools allowing for HSM [5,6]. On the other hand, the machined surface quality is a concept that includes surface roughness and waviness along with surface defects [7].…”

Section: Introductionmentioning

confidence: 99%

“…On the other hand, the machined surface quality is a concept that includes surface roughness and waviness along with surface defects [7]. In practice, the quality of the machined surface is usually described with surface or area roughness parameters (2D, e.g., Ra, Rz, RSm, or 3D, e.g., Sa), and it is one of the basic absolute machinability indicators [5,8]. The influence of AWJM conditions on the material removal rate and the workpiece geometry has been widely studied.…”

Section: Introductionmentioning

confidence: 99%

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Effect of the AWJM Method on the Machined Surface Layer of AZ91D Magnesium Alloy and Simulation of Roughness Parameters Using Neural Networks

et al. 2018

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This paper investigates the effect of change of the abrasive flow rate and the jet feed on the effectiveness of machining of AZ91D casting magnesium alloy. The evaluation of the state of the workpiece surface was based on surface and area roughness parameters (2D and 3D), which provided data on: irregularities formed on the workpiece edge surface (water jet exit), the surface quality after cutting, the workpiece surface chamfering, microhardness of the machined surface, and of specimen cross-sections (along the water jet impact). The process was tested for two parameter settings: abrasive flow rate 50 at cutting speed vf = 5–140 mm/min, and abrasive flow rate 100% (0.5 kg/min) at vf = 5–180 mm/min. The results demonstrate a significant effect of the abrasive flow rate and the jet feed velocity on the quality of machined surface (surface roughness and irregularities). In addition, selected 2D surface roughness parameters were modelled using artificial neural networks (radial basis function and multi-layered perceptron). It has been shown that neural networks are a suitable tool for prediction of surface roughness parameters in abrasive water jet machining (AWJM).

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of the AWJM Method on the Machined Surface Layer of AZ91D Magnesium Alloy and Simulation of Roughness Parameters Using Neural Networks

et al. 2018

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“…The research concentrated on a new forming process of forging an aircraft mount ( Figure 1 a) manufactured from a billet in the form of a sand-cast preform from a high-strength AZ61 grade magnesium alloy. Currently, aircraft mounts presented in Figure 1 b are manufactured by machining from cast elements or by multi-stage forging from wrought billet [ 28 , 29 , 30 , 31 ]. This technology is particularly time, labor, and energy-consuming.…”

Section: Methodsmentioning

confidence: 99%

The Analysis of Deformability, Structure and Properties of AZ61 Cast Magnesium Alloy in a New Hammer Forging Process for Aircraft Mounts

2021

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This article presents the analysis of the deformability, structure and properties of the AZ61 cast magnesium alloy on the example of a new forging process of aircraft mount forgings. It was assumed that their production process would be based on drop forging on a die hammer. Two geometries of preforms, differing in forging degree, were used as the billet for the forging process. It was assumed that using a cast, unformed preform positively affects the deformability of hard-deformable magnesium alloys and flow kinematics during their forging and reduces the number of operations necessary to obtain the correct product. Numerical analysis of the proposed new technology was carried out using DEFORM 3D v.11, a commercial program dedicated to analyzing metal forming processes. The simulations were performed in the conditions of spatial strain, considering the full thermomechanical analysis. The obtained results of numerical tests confirmed the possibility of forming the forgings of aviation mounts from the AZ61 cast magnesium alloy with the proposed technology. They also allowed us to obtain information about the kinematics of the material flow during forming and process parameters, such as strain intensity distribution, temperatures, Cockcroft–Latham criterion and forming energy. The proposed forging process on a die hammer was verified in industrial conditions. The manufactured forgings of aircraft mounts made of AZ61 magnesium alloy were subjected to qualitative tests in terms of their structure, conductivity and mechanical properties.

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“…In particular, the producers of means of transportation began to look for new light-weight materials that would enable reduced fuel consumption and higher technical parameters of vehicles. Mainly produced by casting techniques, 90 per cent of such products were made of magnesium alloy AZ91D (Pekguleryuz et al , 2013; Gziut et al , 2016).…”

Section: Magnesium and Its Applications In The Aircraft Industrymentioning

confidence: 99%

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

Gontarz

Drozdowski²,

Dziubińska

et al. 2018

AEAT

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Purpose The aim of this study is to develop a die forging process for producing aircraft components made of magnesium alloy AZ61A using a screw press. Design/methodology/approach The proposed forging technique has been developed based on the results of a numerical and experimental research. The required forging temperature has been determined by upsetting cylindrical specimens on a screw press to examine both plasticity of the alloy and the quality of its microstructure. The next stage involved performing numerical simulations of the designed forging processes for producing forgings of a door handle and a bracket, both made of magnesium alloy AZ61A. The finite element method based on simulation programme, Deform 3D has been used for numerical modelling. The numerical results revealed that the forgings are free from material overheating and shape defects. In addition to this, the results have also helped determine the regions that are the most prone to cracking. The final stage of the research involved performing forging tests on a screw press under industrial conditions. The forgings of door handles and brackets were made, and then these were tested for their mechanical and structural properties. The results served as a basis for assessing both the viability of the designed technique and the quality of the produced parts. Findings The experimental results demonstrate that aircraft components made of magnesium alloy AZ61A can be produced by die forging on screw presses. The results have been used to determine the fundamental parameters of the process such as the optimum forging temperature, the method of tool heating, the way of cooling parts after the forging process, and the method of thermal treatment. The results of the mechanical and structural tests confirm that the products meet the required quality standards. Practical implications The developed forging technique for alloy AZ61A has been implemented by the forging plant ZOP Co. Ltd in Swidnik (Poland), which specializes in the manufacturing of aircraft components made of non-ferrous metal alloys. Originality/value Currently, the global tendency is to forge magnesium alloys (including alloy AZ61A) on free hydraulic presses using expensive die-heating systems. For this reason, the production efficiency of such forging processes is low, while the manufacturing costs are high. The proposed forging technique for alloy AZ61A is an innovative method for producing forgings using relatively fast and efficient machines (screw presses). The proposed forging method can be implemented by forging plants equipped with standard stocks of tools, which increases the range of potential manufacturers of magnesium alloy products. In addition, this technology is highly efficient and ensures reduced manufacturing costs.

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Analysis of chip fragmentation in AZ91HP alloy milling with respect to reducing the risk of chip ignition

Cited by 11 publications

References 9 publications

Effect of the AWJM Method on the Machined Surface Layer of AZ91D Magnesium Alloy and Simulation of Roughness Parameters Using Neural Networks

Effect of the AWJM Method on the Machined Surface Layer of AZ91D Magnesium Alloy and Simulation of Roughness Parameters Using Neural Networks

The Analysis of Deformability, Structure and Properties of AZ61 Cast Magnesium Alloy in a New Hammer Forging Process for Aircraft Mounts

A study of a new screw press forging process for producing aircraft drop forgings made of magnesium alloy AZ61A

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