Residual Stresses as Essential Criteria for the Evaluation of Production Processes

Leskovar, P.; Ferlan, Dimo; Kovač, Miran

doi:10.1016/s0007-8506(07)62633-x

Cited by 21 publications

(6 citation statements)

References 3 publications

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“…Numerous publications indicated that the quality and lifetime of the dynamically loaded components depends on the properties of the machined surface. 1 Several failures generated by fatigue, creep, cracking, and stress corrosion at the surface of the components could be due to the undesired quality of the surface. 2 Consequently, machined component is first necessary to satisfy the surface integrity requirements.…”

Section: Introductionmentioning

confidence: 99%

Optimization of roller burnishing process using Kriging model to improve surface properties

Nguyen

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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The objective of this work is to investigate the influences of three machining factors (burnishing speed V, feed rate f, and depth of penetration a) on the improved rate of arithmetic average roughness Δ Ra, improved rate of maximum height roughness Δ Ry, and improved rates of surface hardness Δ SH. The internal roller burnishing experiments were conducted with the aid of the computer numerical control machining center and Box–Behnken experimental design. The Kriging models were used to render the highly nonlinear relationships between inputs and outputs. An integrative approach combining a Non-dominated Sorting Genetic Algorithm II and Technique for Order Preference by Similarity to Ideal Solution was adopted to generate a set of feasible optimal solutions and determine the best machining conditions. The scanning electron microscopy images were depicted to investigate the surface morphology at the different conditions. The X-ray diffraction was applied to measure the compressive stresses at the external surface. The results showed that the predicted values of the objectives have good agreement with the experimental ones. High surface quality is characterized by an improved average roughness of 95.80%, an enhancement in the maximum roughness of 91.98%, and an improvement in surface hardness of 45.44%, compared to pre-machined surfaces. The selection of optimum process parameters could help the burnishing operators to save the machining costs and time. The combination of Kriging model, Non-dominated Sorting Genetic Algorithm II, and Technique for Order Preference by Similarity to Ideal Solution is considered as an intelligent approach for modeling and optimization of burnishing processes.

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Section: Introductionmentioning

confidence: 99%

Optimization of roller burnishing process using Kriging model to improve surface properties

Nguyen

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…However, similar to other titanium alloys, Ti-1023 cannot be easily machined because of its high strength, chemical reactivity, and low thermal conductivity. Numerous investigations have confirmed that the performance, longevity, and reliability of machined components during their service life are considerably dependent on their surface quality [3]. Surface integrity requirements (e.g., surface roughness, machining defect, microhardness, microstructure, and residual stress) must be satisfied to eliminate severe failures produced by fatigue, creep, and stress corrosion cracking generated on the surface of components [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Influence of cutting speed and tool wear on the surface integrity of the titanium alloy Ti-1023 during milling

Houchuan

Chen

Zhou

2014

Int J Adv Manuf Technol

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This study focuses on the machined surface integrity of the titanium alloy Ti-10V-2Fe-3Al (Ti-1023) during face milling. Surface roughness, machining defect, microhardness, and microstructure variations are investigated at different cutting speeds and tool average flank wear (VB) values. Experimental results show that surface roughness increases when cutting speed is increased from 40 to 100 m min −1 and decreases when cutting speed is increased from 100 to 300 m min −1 by using a new tool. Moreover, surface roughness values are stable when cutting speed is increased by using a worn tool at VB =0.2 mm and increases when VB is increased. As for defects, the machining defect is determined to be dependent on cutting speed and tool wear directions. Microhardness is decreased to 35 μm beneath the machined surface at different cutting speeds by using a new tool. The influence of tool wear on hardening is significant, with the depth of hardening being less than 55 μm by using a worn tool at VB=0.2 mm and reaching 130 μm at VB=0.35 mm. No significant phase transformation or evident deformation can be observed at different cutting speeds by using a new tool (initial wear). Severe plastic deformation and deep alteration of the microstructure in the machined surface are produced with VB from initial wear to VB=0.35 mm. VB is best maintained at less than 0.2 mm for finish machining of Ti-1023.

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“…In contrast, fewer studies have been done to investigate the surface quality of the hole produced in either normal or high-speed drilling operations of Al-Si alloys. Several studies have shown that the quality and lifetime of the dynamically loaded parts are very much reliant on the properties of the material at the subsurface [4,5]. Factors such as fatigue creep and stress corrosion cracking, which cause failure of the mechanical components, start to affect the component surfaces, and these failure extensions highly depend on the surface integrity of the component [6].…”

Section: Introductionmentioning

confidence: 99%

Surface integrity study of high-speed drilling of Al–Si alloy using HSS drill

Farid

Sharif

Idris

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

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The motivation to replace steel and cast iron with Al–Si alloys for automotive components is part of the attempt to improve fuel economy and reduce emissions. In relation to that, the application of high-speed drilling is considered one of the most-used operations in hole making for automotive parts due to its ability to reduce lead time without sacrificing the hole quality. However, this advantage was offset by the creeping problems encountered during high-speed drilling. Although this issue is addressed accordingly, problems like uncontrollable surface integrity and poor hole quality still exist. Surface integrity studies involved the investigation of surface roughness, metallurgical changes and microhardness of the subsurface of the drilled hole. Significant alternations with respect to the loss of mechanical properties have been observed from the microhardness and microstructure analysis of the drilled hole. Results from this study showed that, in general, drilling parameters have significant effects on the surface quality and integrity of the drilled hole during high-speed drilling of Al–Si using an HSS drill.

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Residual Stresses as Essential Criteria for the Evaluation of Production Processes

Cited by 21 publications

References 3 publications

Optimization of roller burnishing process using Kriging model to improve surface properties

Optimization of roller burnishing process using Kriging model to improve surface properties

Influence of cutting speed and tool wear on the surface integrity of the titanium alloy Ti-1023 during milling

Surface integrity study of high-speed drilling of Al–Si alloy using HSS drill

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