Parametric Analysis of Macro-Geometrical Deviations in Dry Turning of UNS A97075 (Al-Zn) Alloy

Martín-Béjar, Sergio; Vilches, Francisco Javier Trujillo; Gamboa, Carolina Bermudo; Hurtado, Lorenzo Sevilla

doi:10.3390/met9111141

Cited by 8 publications

(13 citation statements)

References 34 publications

(55 reference statements)

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“…These alterations not only affect their geometrical characteristics (at macro and micro scale) but also modify the physical-chemical and mechanical properties of the surface (residual stresses, microstructural alterations, cracks and microcracks, microhardness, corrosion resistance, etc.) [4][5][6]. All these alterations (both material properties and geometry) are part of the surface integrity concept [7][8][9], which is one of the most valued aspects from the point of view of quality requirements, especially in structural elements for aircraft, where these requirements are very high due to functionality and reliability reasons [10].…”

Section: Introductionmentioning

confidence: 99%

Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

et al. 2020

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In this work, an analysis of the cutting speed and feed influence on surface roughness and microhardness of UNS A97075-T6 alloy, turned under dry conditions, was carried out. The results were compared before and after a corrosion process. The influence of these cutting parameters on each of these variables was analyzed, as well as the possible interrelation between them. The microgeometrical deviations showed a general trend to increase with feed. However, no significant modifications were observed as a function of the cutting speed. This trend was softer after the corrosion process, due to the surface alterations produced by pitting corrosion, which resulted in higher dispersion of the experimental data. In addition, a surface microhardness increment was observed in all samples, after machining and before corrosion, regardless of the cutting parameter values. The experimental results revealed that the mechanical effects, produced by the feed, should not be neglected against the thermal effects, produced by the cutting speed, within the range of the tested cutting speed. Finally, the corrosion process negatively affected the microhardness, but it was not possible to establish a direct relationship between the cutting parameters, surface roughness, and microhardness after a corrosion process.

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Section: Introductionmentioning

confidence: 99%

Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

et al. 2020

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“…Additionally, this tool geometry allows comparing the experimental results with previous work in relation to the dry machining of this alloy, carried out by the authors within a wider research project. In these works, a parametric analysis of the surface roughness [24,25], geometrical deviations [32,34,35], micro-hardness [28], fatigue behavior [5], tool wear [22] and chip geometry [29] was performed, keeping the tool geometry constant.…”

Section: Methodsmentioning

confidence: 99%

“…In this work, a similar exponential equation to the one described in [32] was tested, without success, due to convergence problems. A potential equation (Equation ( 1)), as proposed in [34], was also tested. This kind of equations (potential or Taylor equations) is widely used in machining in order to explain the output variables behavior as a function of the cutting parameters (input variables).…”

Section: Form Deviationsmentioning

confidence: 99%

“…The inclusion of the cutting time From the experimental data, it was possible to obtain a mathematical expression to calculate the form deviations (FD) as a function of v c , f and t c . The mathematical expressions found in the literature review, regarding the parametric analysis of the geometrical deviations in the dry machining of this alloy, were exponential and potential equations [30][31][32]34]. In this work, a similar exponential equation to the one described in [32] was tested, without success, due to convergence problems.…”

Section: Form Deviationsmentioning

confidence: 99%

“…Martín-Béjar et al analyzed the influence of the cutting speed and feed on geometrical deviations in the dry turning of the UNS A97075 alloy for high-slenderness specimens. The highest tolerances were obtained when high feed and cutting speed values were combined [34,35]. In that work, a set of parametric equations (potential type) was obtained by the authors.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Vilches

Martín-Béjar

Gamboa

et al. 2021

Metals

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Geometrical tolerances play a very important role in the functionality and assembly of parts made of light alloys for aeronautical applications. These parts are frequently machined in dry conditions. Under these conditions, the tool wear becomes one of the most important variables that influence geometrical tolerances. In this work, the influence of tool wear on roundness, straightness and cylindricity of dry-turned UNS A97075 alloy has been analyzed. The tool wear and form deviations evolution as a function of the cutting parameters and the cutting time has been assessed. In addition, the predominant tool wear mechanisms have been checked. The experimental results revealed that the indirect adhesion wear (BUL and BUE) was the main tool-wear mechanism, with the feed being the most influential cutting parameter. The combination of high feed and low cutting speed values resulted in the highest tool wear. The analyzed form deviations showed a general trend to increase with both cutting parameters. The tool wear and the form deviations tend to increase with the cutting time only within the intermediate range of feed tested. As the main novelty, a relationship between the cutting parameters, the cutting time (and, indirectly, the tool wear) and the analyzed form deviations has been found.

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Coaxiality error analysis and optimization of cylindrical parts of CNC turning process

Rangappa

Patel

Chate

et al. 2022

Int J Adv Manuf Technol

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High precision rotary shafts with precise geometrical tolerances are generally mounted with a micron level clearance between the gears and casing during operation in industrial applications. Dynamics cyclic loads are inevitable in most of these applications which has an adverse effect on the fatigue life of the critical parts. Ensuring close dimensional tolerances and coaxiality during machining is highly desirable, as it affects the rotary characteristics in many applications. Thus, control of coaxiality error plays a vital role in rotating shafts and high precision machine tools. However, use of high precision machining would drastically increase the cost of manufacturing. Thus, a cost-effective machining process that could potentially reduce the coaxiality error is of high industrial importance. The present research efforts made an attempt to achieve minimum coaxiality error on cylindrical machined parts by optimizing parameters (cutting speed, feed rate, depth of cut and cutting tool nose radius). Experiments are planned, viz. central composite design matrix and statistical analysis determine the influence of machine parameters on coaxiality error of high-strength Al 7075 alloy by applying response surface methodology. Feed rate and depth of cut factors showed significant effect on coaxiality error. All machining parameters showed a non-linear effect on coaxiality error, which defines the strong interaction factor effects. The empirical equations derived were used to minimize coaxiality error by determining a set of machining parameters, viz. applying Big-Bang and Big Crunch and Rao (Rao-1, Rao-2 and Rao-3) algorithms. Rao algorithms outperform the Big-Bang and Big Crunch algorithm both in computation effort and solution accuracy. The results of Rao algorithms are experimentally verified, which resulted in reduced coaxiality error equal to 1.013 µm and resulted in 72.6% improvement compared to CCD experiments.

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Parametric Analysis of Macro-Geometrical Deviations in Dry Turning of UNS A97075 (Al-Zn) Alloy

Cited by 8 publications

References 34 publications

Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

Cutting Speed and Feed Influence on Surface Microhardness of Dry-Turned UNS A97075-T6 Alloy

Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Coaxiality error analysis and optimization of cylindrical parts of CNC turning process

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