Review of new developments in machining of aerospace materials

Jemielniak, Krzysztof

doi:10.36897/jme/132905

Cited by 12 publications

(5 citation statements)

References 52 publications

(81 reference statements)

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“…Therefore, further research can also be carried out in this area for developed material and methods of treatment. Future research directions could also include preparation of the materials for different kinds of applications, including applications for different materials, such as advanced ceramics or more precise parts machining [ 37 , 38 , 39 ].…”

Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

et al. 2022

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In the current work, several composites made with fly ash reinforcements are used to conduct electrical discharge machining (EDM) on stainless steel that is commercially accessible. Four composites were prepared with 2.5 to 10% reinforcement of fly ash with steps of 2.5%, copper is used as the matrix material. The specimens were created using the powder metallurgy method, which involved compaction pressures of 450 MPa and 900 °C for 90 min of sintering. The prepared composites are used as the electrode tool for EDM. EDM studies were carried out at two different current amplitudes (5A and 15A) by maintaining the Pulse on time (100 µs), Pulse off time (50 µs), and the depth of machining as 2 mm. The findings show that the addition of more fly ash to the copper matrix increased the material removal rate when cutting the SS304 plate and had a negative impact on the tool. The composite loses its ability to transfer heat during machining as the level of fly ash increases, raising the temperature in the copper matrix and causing the copper to melt more quickly at the electrode interface during machining, leading to increased electrode wear. While tool life was reduced because of the increase in current amplitude, machinability was enhanced.

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Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

et al. 2022

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“…When cutting, almost 80% of the generated heat penetrates to the cutting tool providing its accelerated wear, which contributes to deterioration of the machined surface roughness of machine parts [3]. Hence, the selection of suitable cooling conditions for surface shaping is crucial to obtain favorable results [4].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of the Surface Topography of Ti6Al4V Alloy after the Finish Turning Process under Ecological Conditions

Maruda¹,

Leksycki²,

Wojciechowski³

et al. 2023

Adv. Sci. Technol. Res. J.

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This paper describes findings in the surface topography of Ti6Al4V alloy after finish turning process under dry and MQL (minimum quantity lubrication) machining. The research was fulfilled in the range of variable feeds per revolution of 0.005-0.25 mm/rev and cutting speeds of 40-100 m/min using the depth of cut of 0.25 mm that fits finish processing conditions. The test plan was developed on the way to use the Parameter Space Investigation (PSI) method. The topography features were measured by a Sensofar S Neox optical profilometer using the Imaging Confocal Microscopy technique. Ra parameters and surface roughness profiles as well as 2D images and contour maps were analyzed. Under the studied machining conditions, lower Ra roughness parameters are obtained in the feed rate of 0.005-0.1 mm/rev and cutting speeds of 40-60 m/min. In comparison with dry machining, up to 17% reduction in Ra parameter values was obtained using the MQL method and v c = 70 m/min and f = 0.127 mm/rev as well as v c = 47.5 m/min and f = 0.22 mm/rev. Depending on the machining conditions, peaks and pits as well as feed marks typical for the turning process are observed on the machined surfaces.

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“…Excellent structural properties such as strength, high temperature resistance, creep resistance, low thermal conductivity are challenging from the manufacturing point of view, because they cause high temperature in the cutting zone, the occurrence of large forces and stresses during cutting and strengthening of the surface layer. The phenomena accompanying the machining of superalloys cause rapid tool wear and the occurrence of many defects on the machined surface, negatively affecting the usability and operation of the manufactured components [3,7,8]. In general, superalloys belong to hard-to-machine materials due to the content of elements such as Ni, Co, Cr and Ti, and their machinability is at the level of a few to several % depending on the type of alloy [9].…”

Section: Introductionmentioning

confidence: 99%

Cutting Mechanics when Turning Powder Metallurgy Produced Nickel-Cobalt Base Alloy with a Cubic Boron Nitride Insert

Daź¹,

Habrat²,

Tymczyszyn³

et al. 2022

Adv. Sci. Technol. Res. J.

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For the critical aero-engine parts it's important to understand influence of cutting tools, cutting parameters, tool wear etc. on near surface condition which highly affect fatigue strength and at the same part life-time. New material implemented for the latest designs of aero-engines parts generate challenges for machining processes to fulfil strict requirements of aviation standards. Finish machining is the most important stage of process influencing fatigue strength. Cubic Boron Nitride (cBN) tool are often used for final stage of machining. The objective of this study was analysis of cutting mechanics during finish turning of modern nickel-cobalt based alloy with cBN insert. Observations of cutting tool wear and cutting parameters influence on the components of cutting force, surface roughness and residual stress are presented in this paper.

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Review of new developments in machining of aerospace materials

Cited by 12 publications

References 52 publications

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

Electric Discharge Machining on Stainless Steel Using a Blend of Copper and Fly Ash as the Electrode Material

Evaluation of the Surface Topography of Ti6Al4V Alloy after the Finish Turning Process under Ecological Conditions

Cutting Mechanics when Turning Powder Metallurgy Produced Nickel-Cobalt Base Alloy with a Cubic Boron Nitride Insert

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