Experimental Study of Deflection and Surface Roughness in Thin Wall Machining of Aluminum Alloy

Ramanaiah, B; Manikanta, B.; Sankar, Mamilla Ravi; Malhotra, Manohar L.; Gajrani, Kishor Kumar

doi:10.1016/j.matpr.2017.11.627

Cited by 18 publications

(14 citation statements)

References 13 publications

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“…Surface roughness was reduced by a maximum of 1.626 µm with full support height for Side A, but again saw an average reduction in surface roughness of 1.52 µm on Side B with no major variation for changing support height. While these are small changes in surface roughness value, they do represent a significant improvement [30][31][32]. Comparisons of geometric error and surface roughness to print time were also presented.…”

Section: Discussionmentioning

confidence: 99%

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Vaughan

Saldaña

Nycz

2022

JMMP

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Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed.

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Section: Discussionmentioning

confidence: 99%

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Vaughan

Saldaña

Nycz

2022

JMMP

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“…They have an excellent structural homogeneity and an excellent strength to weight ratio. In thin-wall machining, the thickness of the wall decreases gradually during cutting, this makes this process a very complicated process [12].…”

Section: Thin Walled Machiningmentioning

confidence: 99%

A Review on Thin Walled Cryogenic Machining on Inconel or Aerospace Materials

Budiman

Mohruni

2020

J. Mech. Sci. Eng.

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Cutting fluids are widely used in machining processes throughout the world. However, this cutting liquid is the source of many environmental pollution problems. In order to reduce or eliminate the effect produced by cutting fluids, it is necessary to switch to a continuous machining technique such as using small amounts of cutting fluid, liquid nitrogen, vegetable oil or compressed air as a cooling lubrication medium. Cryogenic coolant is found to be more efficient, economical, cost-effective and environmentally friendly when compared to the conventional coolant, especially in mass production. In machining difficult-to-cut materials such as thin walled materials for the aerospace industry, cooling applications are needed. Ni-based super alloy, Inconel is a material for aerospace applications because of its high durability to wear and material that is resistant to oxidation and corrosion at high temperatures. This paper presents a review and explanation of thin wall machining using cryogenic cooling systems on Inconel or aerospace materials.

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“…Its thickness is smaller at the base and increases towards the upper edge of the wall. The value of the elastic deformation during machining depends on the mechanical properties of the materials being machined, i.e., in the considered case, the various aluminum alloys [ 4 , 5 , 6 , 7 ]. Figure 1 shows the deformation of a thin wall under the influence of the cutting force during machining.…”

Section: Introductionmentioning

confidence: 99%

A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys

et al. 2021

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In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to that of other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.

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Experimental Study of Deflection and Surface Roughness in Thin Wall Machining of Aluminum Alloy

Cited by 18 publications

References 13 publications

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

A Review on Thin Walled Cryogenic Machining on Inconel or Aerospace Materials

A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys

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