Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness

Nowakowski, Łukasz; Bartoszuk, Marian; Skrzyniarz, Michał; Błasiak, Sławomir; Vasileva, Dimka

doi:10.3390/ma15103626

Cited by 6 publications

(5 citation statements)

References 27 publications

(26 reference statements)

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“…where s 2 1 , s 2 2 were the variances of the studied variable in the samples randomly selected from the first and second populations (s 2 1 was the variance with a greater value than s 2 2 ). Based on the adopted significance level α and the determined numbers of degrees of freedom f 1 and f 2 , the critical value F cr was established.…”

Section: Resultsmentioning

confidence: 99%

“…A rapid development of machining processes in terms of product dimensional and shape accuracy has led to the wide application of these processes in various industrial branches, such as automotive, aviation, military, and electronics [ 1 , 2 , 3 , 4 ]. When it comes to the manufacture of thin-walled parts, the greatest problem is posed by strain generation during machining operations, particularly milling.…”

Section: Introductionmentioning

confidence: 99%

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Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Zawada-Michałowska,

Pieśko,

Mrówka-Nowotnik

et al. 2024

Materials

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show abstract

“…From a review of the literature, it is clear that conventional machining is still the major manufacturing process for many types of materials. The most popular machining operations are turning, milling [21][22][23], drilling [24], grinding, and polishing [25].…”

Section: Introductionmentioning

confidence: 99%

Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6)

et al. 2023

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Drilling with standard twist drill bits is the most common method to create cylindrical holes. With the constant development of additive manufacturing technologies and easier access to additive manufacturing equipment, it is now possible to design and fabricate solid tools suitable for various machining applications. Specially designed 3D printed drill bits seem more convenient for standard and nonstandard drilling operations than conventionally made tools. The study described in this article aimed to analyze the performance of a solid twist drill bit made from steel 1.2709 using direct metal laser melting (DMLM), which was compared with that of a drill bit manufactured conventionally. The experiments involved assessing the dimensional and geometric accuracy of the holes made by the two types of drill bits and comparing the forces and torques occurring during the drilling of holes in cast polyamide 6 (PA6).

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“…The analysis of the influence of the process parameters shows that the feed per tooth has the greatest influence on surface roughness, whereas the effect of the axial depth of cut is the lowest. Many studies have aimed to determine the influence of the key machining process parameters, i.e., the feed rate, the cutting speed, and the depth of cut, on the roughness of milled surfaces [10]. Kao et al [11] indicate that in milling, surface roughness can be predicted from the cutting forces.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Relative Displacements and the Minimum Chip Thickness on the Surface Texture in Shoulder Milling

Nowakowski,

Blasiak,

Skrzyniarz

2023

Materials

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The formation of surface texture in milling is a complex process affected by numerous factors. This paper focuses on the surface roughness of X37CrMoV51 steel machined by shoulder milling. The aim of the study was to develop a mathematical model to predict the surface roughness parameter Ra. The proposed model for predicting the surface roughness parameter Ra in shoulder milling takes into account the feed per tooth, fz, the corner radius, rε, and the actual number of inserts involved in the material removal process as well as hmin and D(ξ). The correlation coefficient between the theoretical and experimental data was high (0.96). The milling tests were carried out on a three-axis vertical milling machine using a square shoulder face mill. The geometric analysis of the face mill shows that at a feed rate of 0.04 mm/tooth, cutting was performed by three out of five inserts, and when the feed rate exceeded 0.12 mm/tooth, material was removed by all inserts. The minimum chip thickness parameter and the standard deviation of the relative displacement increased as the feed increased. Over the whole range of feeds per tooth, the displacement increased by 0.63 µm. Higher cutting speeds resulted in lower minimum chip thicknesses and the average standard deviation of the relative displacements for the whole range of cutting speeds was 2 μm.

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Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness

Cited by 6 publications

References 27 publications

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates

Analyzing the Potential of Drill Bits 3D Printed Using the Direct Metal Laser Melting (DMLM) Technology to Drill Holes in Polyamide 6 (PA6)

Influence of the Relative Displacements and the Minimum Chip Thickness on the Surface Texture in Shoulder Milling

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