Repairing Hybrid Mg–Al–Mg Components Using Sustainable Cooling Systems

Abstract

This paper focused on the maintenance or repair of holes made using hybrid Mg–Al–Mg components by drilling, using two sustainable cooling techniques (dry machining and cold compressed air) and taking surface roughness on the inside of the holes as the response variable. The novelty of the work is in proving that the repair operations of the multi-material components (magnesium–aluminum–magnesium) and the parts made of aluminum and magnesium (separately) but assembled to form a higher component can be done simultaneously, thus reducing the time and cost of the assembly and disassembly of this type of component. The study is based on a design of experiments (DOE) defined as a product of a full factorial 23 and a block of two factors (3 × 2). Based on our findings, we propose that the analyzed operations are feasible under sustainable conditions and, in particular, under dry machining. Also, the results depend on the machining order.

Thicknesses/Roughness Relationship in Mg-Al-Mg and Mg-Ti-Mg Hybrid Component Plates for Drilled Aeronautical Lightweight Parts

“…In each iteration, the statistically less significant effect was excluded, in case it had a p-value higher than 0.05. From the analysis of variance, it is concluded that the two significant factors in the process are the location regarding the insert, LRI, and the type of cooling system, C. These results are consistent with previous works [58,60] and there is also an interaction, unknown so far, between the type of cooling system, C, and the location regarding the specimen, LRS. Table 6 shows the percentage of variability attributed to each factor obtained as a percentage of the sum of squares of each significant factor with respect to the total sum of squares of the significant effects.…”

“…This study is part of a research project that includes different lightweight structural materials, machining processes, and cooling/lubrication systems [18,19,57,58,60]. The methodology used is similar to the one followed in previous works in which the bases that provided the initial knowledge for this work were established.…”

“…The methodology used is similar to the one followed in previous works in which the bases that provided the initial knowledge for this work were established. In previous studies within the same project, and using a similar methodology to make the individual studies comparable, the influence factors on the turning of Mg-Al specimens were studied [19], the influence of the tool on the drilling of magnesium alloy parts was investigated [20], the best process parameters for re-drilling on titanium parts by dry machining were investigated to eliminate the use of lubricant/coolant fluids and thus make the process more sustainable and economical [18], and the parameters with the most influence on the re-drilling of hybrid multimaterial Mg-Al-Mg compounds with various re-drilling diameters were investigated [58,60]. This methodology is based on the Taguchi methodology and the Montgomery guidelines [59], to carry out a study in which the results can be compared with each other.…”

Special Issue of the Manufacturing Engineering Society 2019 (SIMES-2019)

“…In this Special Issue of the journal Materials, 29 contributions to cutting-edge advances in different fields of the manufacturing engineering have been collected. In particular, in additive manufacturing and 3D printing [4][5][6][7][8][9][10][11]; sustainable and green manufacturing [12][13][14][15][16]; metrology and quality in manufacturing [17][18][19][20][21]; advances and innovations in manufacturing processes [22][23][24][25]; manufacturing of new materials [26][27][28]; design, modeling, and simulation in manufacturing engineering [29,30] industry 4.0 [31] and manufacturing engineering and society [32]. Among all of them, the topic additive manufacturing and 3D printing stands out for the number of contributions it has had in this Special Issue showing the interest that this topic arouses, currently, among researchers, the industry and the public in general.…”

“…The next topics by the number of contributions are sustainable and green manufacturing and metrology and quality in manufacturing with five contributions each. The first one gathers four works about new sustainable lubrication/cooling techniques used in removal processes [12][13][14][15] and the other about reusing waste in ecological cement [16]. The second one collects research about the optimization of laser tracker location on verification process [17], estimation of an upper bound to the value of the step potentials from grounding resistance measurements [18], enhanced positioning algorithm by mesh elements, recalculation and angle error orientation [19], industrial calibration procedure for confocal microscopes [20] and, finally, the development and validation of a calibration gauge for length measurement systems [21].…”