Abstract
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.
Highlights
IntroductionManufacturing processes have a high influence on the surface integrity of manufactured parts, altering both the geometrical and physicochemical properties of the surface
Manufacturing processes have a high influence on the surface integrity of manufactured parts, altering both the geometrical and physicochemical properties of the surface.These changes may affect the functionality, reliability and final cost of the product [1].Geometrical deviations can be considered at both micro-scale and macro-scale levels [2]
The influence of tool wear on several form deviations of dry-turned UNS A97075 alloy specimens has been studied in this work
Summary
Manufacturing processes have a high influence on the surface integrity of manufactured parts, altering both the geometrical and physicochemical properties of the surface. These types of general models are very difficult to obtain in machining, given the large number of variables involved in these processes and the synergy between them These equations are easy to obtain and have an immediate practical application in the industry, since they allow obtaining, under the specified conditions, the values of the cutting parameters to manufacture fatigue test specimens, complying with the geometric tolerances required in the standards [6]. The main novelty of this work lies in the inclusion of the machining time and, indirectly, the tool wear in the study of the form of tolerances as a function 4ofofthe cutting parameters, which has not been addressed in previous research This kind of information is highly demanded by the industry
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