Capacitation of Flexibles Fixtures for Its Use in High Quality Machining Processes: An Application Case of the Industry 4.0. Paradigm

Rubio-Mateos, Antonio; Rivero, A.; Llana, Irene Del Sol; Ukar, Eneko; Mentxaka, Aitzol Lamikiz

doi:10.6036/8824

Cited by 7 publications

(5 citation statements)

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“…Similarly, distance sensors are used to act on the depth of cut, so when the distance recorded is not in the expected range the system automatically modifies the depth of cut improving the dimensional accuracy [47,48]. Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components DOI: http://dx.doi.org /10.5772/intechopen.93719 Finally, the cutting power and the cutting force signals can provide information about the tool wear or the process temperature improving the dimensional accuracy.…”

Section: Advanced Milling Techniquesmentioning

confidence: 99%

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

Salguero¹,

Sol²,

Gómez-Parra³

et al. 2021

Advanced Aluminium Composites and Alloys

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Machining operations are chosen by aircraft manufacturers worldwide to process light aluminum alloys. This type of materials presents good characteristics in terms of weight and physicochemical properties, which combined with a low cost ratio making them irreplaceable in aircraft elements with a high structural commitment. Conventional machining processes such as drilling, milling and turning are widely used for aeronautical parts manufacturing. High quality requirements are usually demanded for these kinds of components but aluminum alloys may present some machinability issues, basically associated to the heat generated during the process. Among others, surface quality and geometrical deviations are highly influenced by the condition of the cutting-tool, its wear and the cutting parameters. Consequently, the understanding of the relationship among the process parameters, the quality features and the main wear mechanism is a key factor for the improvement in the productivity. In this chapter, the fundamental issues of drilling, milling and turning are addressed, dealing with the relationship between cutting parameters, wear phenomena and micro and macro geometrical deviations.

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Section: Advanced Milling Techniquesmentioning

confidence: 99%

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

Salguero¹,

Sol²,

Gómez-Parra³

et al. 2021

Advanced Aluminium Composites and Alloys

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“…This last effect was mainly caused by the thermal expansion of the spindle, as it increased combined with the revolutions [42]. This error can be compensated previous to the machining [43] or even with in-process tool position adjustments [44,45]. only exception was the effect of spindle speed in the case of the rubber A as its p-value was under α, see Table 4 values in bold.…”

Section: Thickness Errormentioning

confidence: 99%

Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

Rubio-Mateos

Rivero

Ukar

et al. 2020

Metals

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In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.

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“…This fact explains the part thinning, rejecting the direct effect of the cutting speed. Though the thermal expansion of the spindle was identified as an influencing parameter for the increase of the final average thickness error of the part, this error was easy to compensate when studying the elongation curves of the spindle and considering them in the CAM design [30] or implementing error compensation rules in the machine control [5]. Once the average error-not directly related to the cutting parameters-can be compensated, the target is to get a homogeneous thickness distribution.…”

Section: Final Thickness Errormentioning

confidence: 99%

“…In fact, different projects and research studies have invested hundreds of thousands of euros to remove chemical milling, designing specific clamping systems to ensure surface quality and dimensional requirements while maintaining clamping flexibility. These systems are focused on twin-machining heads [2,3], magnetic slaves [4] or flexible vacuum beds [5] that control the deflection of the part avoiding overcut during the operation.…”

Section: Introductionmentioning

confidence: 99%

Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

Sol

Rivero

Gámez

2019

Metals

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Nowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.

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Capacitation of Flexibles Fixtures for Its Use in High Quality Machining Processes: An Application Case of the Industry 4.0. Paradigm

Cited by 7 publications

References 0 publications

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates

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