Investigation on surface roughness, residual stress and fatigue property of milling in-situ TiB2/7050Al metal matrix composites

Xiong, Yifeng; Wang, Wenhu; Shi, Yaoyao; Jiang, Ruisong; Shan, Chenwei; Liu, Xiaofen; Lin, Kunyang

doi:10.1016/j.cja.2020.08.046

Cited by 32 publications

(13 citation statements)

References 23 publications

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“…Two main points discussed by the authors were that (a) surface compressive residual stresses decreased by 81 MPa as the feed rate increased from 0.02 to 0.1 mm/rev as a larger removal rate raises the temperature to induce tensile stress, and that (b) surface tensile residual stress increased with an increase in cutting speed due to the high heat generated during milling at higher cutting speeds. The cutting speed effect was similarly observed by Xiong et al [ 19 ]. Lin et al [ 20 ] analyzed the effect of tool nose radius and tool wear on the residual stress distribution during turning of 7075 matrix reinforced with TiB 2 particles.…”

Section: Introductionsupporting

confidence: 68%

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

et al. 2023

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The addition of hollow aluminium oxide bubbles to the 7075 aluminium matrix results in a lightweight syntactic foam with a reduced density and an increased peak compression strength. The presence of ceramic bubbles also aids in a reduced coefficient of thermal expansion and thermal conductivity in comparison to aluminium alloys. In spite of their enhanced material properties, the inclusion of hollow aluminium oxide bubbles presents the challenge of poor machinability. In order to elucidate the problem of poor surface machinability, an attempt has been made to develop a thermo-mechanical finite element machining model using AdvantEdgeTM software with which surface quality and machined syntactic foam material can be analyzed. If the novel model developed is combined with virtual reality technology, CNC technicians can observe the machining results to evaluate and optimize the machining program. The main novelty behind this software is that the material foam is assumed as a homogeneous material model for simplifying the material model as a complex heterogeneous material system. The input parameters used in this study are cutting speed, feed, average size and volume fraction of hollow aluminium oxide bubbles, and coolant. For the output parameters, the numerical analysis showed a 6.24% increase in peak tensile machining induced stress as well as a 51.49% increase in peak cutting temperature as cutting speed (25 m/min to 100 m/min) and uncut chip thickness (0.07 mm to 0.2 mm) were increased. The average size and volume fraction of hollow aluminium oxide bubbles showed a significant impact on the magnitude of cutting forces and the depth of tensile induced stress distribution. It was observed on the machined surface that, as the average size of hollow aluminium oxide bubbles became coarser, the peak machining induced tensile stress on the cut surface reduced by 4.47%. It was also noted that an increase in the volume fraction of hollow aluminium oxide bubbles led to an increase in both the peak machining induced tensile stress and the peak cutting temperature by 29.36% and 20.11%, respectively. This study also showed the influence of the ceramic hollow bubbles on plastic deformation behavior in 7075 aluminium matrix; the machining conditions for obtaining a favorable stress distribution in the machined surface and sub-surface of 7075 closed cell syntactic foam are also presented.

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Section: Introductionsupporting

confidence: 68%

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

et al. 2023

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“…It was also possible to identify that the surface finish at this speed does not show any discrepancy along its surface ( Figure 13). A better finish is expected with higher speeds, this result was also obtained by Xiong et al (2020). According to the literature, the roughness in the front milling can be calculated by Equation 2, where re is the tool tip radius and fz is the feed.…”

Section: Roughnessmentioning

confidence: 57%

“…The deposition rate with this process for aluminum and steel is from 1 kg/h to 4 kg/h, however it is possible to achieve rates above 10 kg/h, but the dimensional accuracy is low (Williams et al 2016). As a disadvantage, there is the residual stress inserted in the part due to the shrinkage during cooling, which is greater along the direction of position (Liu et al 2020). Distortions in dimensions result in poor tolerance quality while residual stress affects part performance (Colegrove et al 2014).…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Additive Manufacturing Parts Machinability using Automated GMAW ER70S-6 with Nodular Cast Iron

Dttmann

Gomes

2021

UPjeng

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Through additive manufacturing is possible to obtain products with few material waste, low production time and great flexibility in geometry. In recent years, the application of arc welding processes has been studied as additive manufacturing techniques for metals. When compared to laser welding processes, they have low equipment cost, high deposition rate, however a low surface quality. This work proposes to study the machinability of additive manufacturing parts using automated GMAW. The deposition was carried out using a robotic arm, using ER70S-6' wire with a substrate of nodular cast iron. Two deposition strategies were carried out, one alternating the passes directions and the other one depositing in the same direction. The machining process used was milling in a three axis machining center. The deposition strategy had an influence on the parts surface finish after machining, as well as on the tool life.

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“…After milling process, the surface roughness was measured with the white light interferometer (MFT-5000). According to Xiong [32], 2D surface roughness value (Ra & Rq) was not only affected by the measurement location, but also impacted by the measurement direction. In addition, the 2D roughness value would differ a lot with sampling line crossing and not crossing groove, material smearing, cutting edge mark and protuberance defects.…”

Section: Characterization Of Hsd Milling Surface Roughnessmentioning

confidence: 99%

Specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

Zhang¹,

Kang²,

Cao³

et al. 2022

Preprint

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Existing research on coated tools does not predict data while exploring the changing rules. As well as the traditional cutting process parameters neither guarantees the surface quality of the 30CrMnSiNi2A nor attains high material removal rate (MRR). Accurate control and prediction of workpiece three-dimensional surface roughness (Sq) and specific cutting energy consumption (SCEC) are of vital significance to improve quality, reduce cost and improve efficiency. Here, according to the new SCEC calculation model and the influence of measuring position on Sq, the SCEC and Sq values are accurately obtained. Then, based on the idea of fitting formula, the influence of cutting parameters on SCEC and Sq in high-speed dry (HSD) milling of 30CrMnSiNi2A steel is analyzed according to CVD and PVD coated inserts. Finally, the SCEC and Sq prediction models considering coating type, cutting speed, feed per tooth and cutting width are established by using the XGBoost algorithm. The R2 values of SCEC and Sq are 0.92465 and 0.91527, respectively, indicating that the model has a good prediction effect on experimental data. The feasibility of HSD milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is verified by analyzing SCEC, Sq and cutting temperature, which provides experimental basis for high efficiency and high precision machining of 30CrMnSiNi2A steel.

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Investigation on surface roughness, residual stress and fatigue property of milling in-situ TiB2/7050Al metal matrix composites

Cited by 32 publications

References 23 publications

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

Evaluation of Additive Manufacturing Parts Machinability using Automated GMAW ER70S-6 with Nodular Cast Iron

Specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

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