Machining of Aluminum alloys: a review

Ni‐based superalloy Inconel 718 is renowned owing to its admirable physical and mechanical properties at higher temperatures. Various industries including aerospace and automobile are using this superalloy in gas turbines and other components. Meanwhile, the excellent mechanical properties (high strength and hardness) of Inconel 718 cause poor machined surface integrity and machinability, which have always been an interesting task in the machining of superalloys. Countless studies are performed on the machinability of Inconel 718 defining optimal cutting parameters and for the advancement of a better understanding of superalloys’ machining like Inconel 718. Herein, a comprehensive review regarding the machining trends of Inconel 718 is offered and the causes of the various symbolic machining parameters are cited on numerous machinability features concerning the modern literature and the earlier one. The machining characteristics including cutting tool wear, cutting forces, and surface reliability such as microhardness, surface roughness, and residual stresses are reviewed.

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Simulation-Based Investigation of the Distortion of Milled Thin-Walled Aluminum Structural Parts Due to Residual Stresses

Weber¹,

Kirsch²,

D’Elia

et al. 2023

Proceedings of the 3rd Conference on Physical Modeling for Virtual Manufacturing Systems and Processes

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Nowadays, aluminum components in aircraft are mainly found in the form of thin-walled monolithic structural parts of the internal fuselage and the wings as spars and ribs [1]. This is because these components have excellent material properties for lightweight applications, such as a high strength-to-weight ratio and good corrosion resistance [2]. A typical manufacturing process to produce such structural components is milling. For these weight-optimized, monolithic components, up to 95% of the material is removed by machining [3]. The challenge with these thin-walled structural components, which are up to 14 m long, is that part distortion can occur because of the manufacturing-specific process chain [4]. Residual stresses due to machining and upstream processes such as forming, and heat-treatments are known to be the key factor for causing those distortions [5].In this research the effect of the residual stresses, the machining strategy, the part topology and the geometry, including the wall-thickness, on distortion were investigated experimentally, and simulatively by validated virtual models based on the finite-element method. Those models can then be used to predict the distortion. At the end distortion minimization techniques were derived.

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Machining of Aluminum alloys: a review

Cited by 154 publications

References 16 publications

Modeling and Optimization Process in Milling

Modeling and Optimization Process in Milling

Influence of Machining Parameters on Machinability of Inconel 718—A Review

Simulation-Based Investigation of the Distortion of Milled Thin-Walled Aluminum Structural Parts Due to Residual Stresses

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