Analysis on high-speed face-milling of 7075-T6 aluminum using carbide and diamond cutters

Rao, Balkrishna C.; Shin, Yung C.

doi:10.1016/s0890-6955(01)00033-5

Cited by 135 publications

(67 citation statements)

References 15 publications

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“…Then the deformation zone is unloaded, which leads to a state of compressive stress. Although Rao and Shin [13] also reported compressive residual stresses in samples of 7075-T6 alloy milled at high speed, the evaluation was limited to only one stress component. Figure 6(a) shows the normal component σ x .…”

Section: Resultsmentioning

confidence: 99%

“…The results obtained through this model were compared with experimental results derived using the hole-drilling technique. Then, Rao and Shin [13] carried out an analytical and experimental study in samples of AA 7075-T6 alloy milled with a single insert fly-cutter. In this work, high-speed cutting process mechanics is presented, and residual stresses were evaluated in function of different cutting parameters.…”

Section: Related Workmentioning

confidence: 99%

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Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Díaz¹,

Mammana²,

Guidobono³

2012

MME

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In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.

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Section: Resultsmentioning

confidence: 99%

Section: Related Workmentioning

confidence: 99%

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Díaz¹,

Mammana²,

Guidobono³

2012

MME

View full text Add to dashboard Cite

show abstract

“…Machining operations would generate geometric distortions and a high level of surface residual stresses, which has been studied extensively in terms of machining techniques (El-Khabeery and Fattouh, 1989;Rao and Shin, 2001; Ee et al, 2005;Ulutan et al, 2007;Denkena et al, 2008;Tang et al, 2009) but has not yet been considered in springback predictions for CAF. The machined plate normally contains different thickness at different sections.…”

Section: Introductionmentioning

confidence: 99%

Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming

Lam

Shi

Lin

et al. 2015

International Journal of Mechanical Sciences

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Abstract. Springback behaviour of surface-machined 7B04-T651 aluminium plates of 3 to 8 mm thicknesses, creep-age formed under a single curvature bending radius of 1200 mm, has been experimentally investigated. The surface residual stress levels of the plates have been measured and the typical residual stress distribution and values in 7000-series aluminium alloys have been reviewed and analysed. Finite element models have been developed to simulate creep-age forming (CAF) processes and predict the amount of springback in the physical CAF test. Machining-induced residual stresses and distortion have been considered in the finite element models. This paper presents a first attempt to study the effect of machining-induced residual stresses on the errors of springback prediction in CAF of 7000-series aluminium alloy panel components. It has been found that the effect of machininginduced residual stresses on the accuracy of springback prediction is related to the initial loading stress levels in CAF. In addition, when the initial distortion conforms to the loading curvature, an opposing effect on the material's deformation is observed. Creep-ageing material constant related to effective creep strain rate.1 Creep-ageing material constant related to rate of age hardening.2 Creep-ageing material constant related to the depletion of solute into precipitate.3 Creep-ageing material constant related to rate of precipitate growth.4 Creep-ageing material constant controlling the effect of dislocation density (or creep) on precipitate nucleation and growth.5 Creep-ageing material constant related to rate of dislocation density.Creep-ageing material constant related to rate of dislocation hardening.Bending radius of forming tool.̅ , ̅ Normalised precipitate size and its rate term respectively. ̅ 0 Initial value for normalised precipitate size.Radius of revolvement of workheads of the flexible form tool.Creep-ageing time.1 , 2 , 3 , 4 Time of loading, heating, cooling and unloading respectively. Artificial ageing time.Solution heat treatment time., , Translational degrees of freedom in Cartesian coordinates., , Rotational degrees of freedom in Cartesian coordinates.Poisson's ratio., , Cartesian coordinates., positions of the lower and upper splines respectively.

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“…Due to the high ductility and sticky nature, high chemical activity of the aluminum alloy, there are many machining problems such as tool irregular wear, sever adhesion on the tool face and burrs and marks of pressing/extrusion on the machined surface [1][2]. These problems have a great influence on the efficiency, quality and cost when machining this kind of material.…”

Section: Introductionmentioning

confidence: 99%

Cutting Temperature investigation when Heavy Milling Welded Aluminum-Thin- Walled Hollow Structure

Ge¹,

Hou²,

Jia³

et al. 2015

Proceedings of the 3rd International Conference on Material, Mechanical and Manufacturing Engineering

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Analysis on high-speed face-milling of 7075-T6 aluminum using carbide and diamond cutters

Cited by 135 publications

References 15 publications

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming

Cutting Temperature investigation when Heavy Milling Welded Aluminum-Thin- Walled Hollow Structure

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