Influence Of Tool Geometry Research Articles

The Influence of Tool Geometry for Refill Friction Stir Spot Welding (RFSSW) on Weld Properties During Joining Thin Sheets of Aluminum Alloys

1. Financial support of The National Centre for Research and Development, European Union, PZL Mielec / a Sikorsky Company, in the framework of European Regional Development Fund Project “Advanced techniques for the fabrication of airframe structures using innovative friction stir welding (FSW) technology”, no. INNOLOT/I/4/NCBR/2013 is gratefully acknowledged.

Study on the Machinability of SMC Composites During Hole Milling: Influence of Tool Geometry and Machining Parameters

The machining of composite materials is generally performed to obtain the required geometry and dimensional tolerances. This paper applies the Taguchi method to investigate the effects of end-milling parameters on the machinability outputs of chopped glass fiber-reinforced polymer composites. The main aim is to investigate the machinability and defects generated by four different end-mill tool geometries when applying hole expansion on A-Class Sheet Mold Compound (SMC) composites. The resultant force, surface roughness, and peel-up delamination behavior were evaluated under different cutting conditions in milling operations, while the milling experiments were conducted under different parameters and levels according to the Taguchi method. The contribution ratio of parameters on machinability outputs was analyzed statistically via analysis of variance and regression analysis. The most suitable cutting conditions to achieve a high-quality hole in the least amount of machining time on an SMC composite include higher cutting speed, lower feed rate, higher number of teeth—as with six-fluted helix and eight-fluted burr-style end mills—and down-milling with CCW circular interpolation.

Simulation and Experimental Research on the Influence of Tool Geometries on the Cutting Force of High Temperature Alloy

For the difficult-to-process characteristics of the aero-engine turbine disk plank produced by Nickel-based superalloy GH4169 that appeared in the turning process, the numerical simulation and experimental research were conducted in this paper. The two-dimensional orthogonal cutting model of the Nickel-based superalloy GH4169 was established to conduct the single factor experiment, in which the rake angle and tip radius were as the single variable, and the influence of cutting force caused by the rake angle and tip radius was researched by the finite element analysis software ABAQUS. The correctness of the simulation modal was verified by the comparison of the cutting force data obtained in simulation and the experimental result. The study demonstrates the fact that the back force Fy will decrease while the feed force Fy and the main cutting forceFc increase slowly with the increase of the rake angle. The back force Fy will increase with the increase of the tip radius. In addition, the changing trend of cutting force obtained in the experiment was consistent with that of simulation. Under the experimental conditions, the rake angle of 10° and tip radius 0.4mm were suitable processing parameters for machining the Nickel-based superalloy GH4169.

Influence of tool material and geometry on micro-textured surface in radial ultrasonic vibration-assisted turning

Surface texturing has been widely used to fabricate functional surface, which can improve the friction performance or achieve suitable wettability for different mechanical products. In order to fabricate micro-textured surface in an efficient and cost-effective way, a surface texturing method of radial ultrasonic vibration-assisted turning (RUVT) was proposed. The texturing generation mechanism of RUVT was firstly analyzed through a theoretical model. Then, the influence of tool geometry on micro-texture, including clearance angle and nose radius, was further characterized by a surface topography simulation. The simulated and experimental results show that the clearance angle and nose radius have important effect on the shape and width of micro-dimples of the textured surface, respectively. Compared with a cemented carbide tool, the diamond tool is more preferable to be used to generate well shaped and distributed micro-dimples, because of its sharp cutting edge and less wear during the texturing process. The experimental textured surfaces, fabricated under different clearance angles of 0°, 7° and 20°, also have shown different wetting properties through wettability tests. It is verified that the RUVT can be a cost-effective texturing way for fast generation of micro-dimpled surfaces by choosing appropriate tool parameters.

The influence of tool geometry and process parameters on joined sheets by clinching

In this work, the process of clinching was studied through practical experiments and also by computer simulation using finite element method (FEM). The influence of different joint geometries and process parameters on the strength of joints joined by clinching was studied. Subsequently, a practical study with the aim of comparing its results with FEM results was carried out. It was possible to observe that the geometry of the clinching tool and the choice of process parameters influence the interlocking strength. FEM simulations showed similar results to the practical experiments and also avoided the manufacture of different tools and the accomplishment of several experiments.

搅拌摩擦焊接过程搅拌头几何对搅拌头受力的影响

搅拌摩擦焊接过程搅拌头几何对搅拌头受力的影响

Modelling of static and dynamic milling forces in inclined operations with circle-segment end mills

Circle-segment mills are new solid end mills with oval profiles that begin to substitute ball end-mills in some applications. They are intended for high performance finishing of complex surfaces in 5-axis operations. This work deals with the mechanical characterization of such tools. A time domain model is proposed to predict tool's cutting behavior in static and dynamic conditions. The influence of tool geometry, orientation tilt and lead angles, modal parameters and cutting conditions was modeled. As a result, an accurate method is presented to predict forces and vibrations in inclined milling operations. This can be very useful to avoid vibrations during the last steps in the manufacturing of blisk and impellers that may harm the workpiece quality. Theoretical simulations against experimental data are provided to validate the approach for this new tool concept.

Influence of tool geometry and processing parameters on welding defects and mechanical properties for friction stir welding of 6061 Aluminium alloy

Friction stir welding (FSW) is a form of solid state welding process for joining metals, alloys, and selective composites. Over the years, FSW development has provided an improved way of producing welding joints, and consequently got accepted in numerous industries such as aerospace, automotive, rail and marine etc. In FSW, the base metal properties control the material’s plastic flow under the influence of a rotating tool whereas, the process and tool parameters play a vital role in the quality of weld. In the current investigation, an array of square butt joints of 6061 Aluminum alloy was to be welded under varying FSW process and tool geometry related parameters, after which the resulting weld was evaluated for the corresponding mechanical properties and welding defects. The study incorporates FSW process and tool parameters such as welding speed, pin height and pin thread pitch as input parameters. However, the weld quality related defects and mechanical properties were treated as output parameters. The experimentation paves way to investigate the correlation between the inputs and the outputs. The correlation between inputs and outputs were used as tool to predict the optimized FSW process and tool parameters for a desired weld output of the base metals under investigation. The study also provides reflection on the effect of said parameters on a welding defect such as wormhole.

Investigations on drilling of hemp/glass hybrid composites

ABSTRACTThe present study aimed to examine the influence of tool geometry, spindle speed and feed on thrust force (TF) and delamination in hybrid hemp-glass composites. The pure glass polyester, pure hemp polyester and hybrid hemp/glass polyester composite specimens were prepared using hand layup technique. The drilling experiments were performed according to the full factorial design. Analysis of variance (ANOVA) was used to determine the impact of layering arrangement of fibers, feed (0.06, 0.18, 0.3 mm/rev), speed (1000, 3000, 5000 rpm), tool geometry (Plexi Point, Brad, Parabolic) and their interactions on TF and delamination. It was observed that drill geometry is major determinant for TF and delamination. Empirical models were developed using regression analysis and grey relational analysis was performed for optimizing the input parameters for TF and delamination at entry and exit.

Influence of tool geometry on material flow and mechanical properties of friction stir welded Al-Cu bimetals

Al-Cu bimetallic sheets were friction stir welded by three different kinds of pin profiles (threaded cylindrical, threaded conical and pyramidal). Among the three pin geometries used, the threaded conical tool provided the best compromise between the different material flow regions and thereby the fewest defects and the highest weld strength were obtained with this tool. As the cylindrical tool has the lowest contact area, it resulted in insufficient material flow around the pin and tunnel defects appeared on the advancing side. A downward material flow is essential to avoid tunnel defects on the advancing side. It was not possible to obtain a weld efficiency of one hundred percent due to the existence of a micro-void analogous to kissing bond on the retreating side. This flaw is a result of a downward material flow, which is essential to obtain a defect-less weld on the advancing side. Torque values and temperatures during welding were directly related to the downward material flow. In samples without tunnel defects on the advancing side, higher values of torque and temperature were recorded.

Optimisation of milling parameters with multi-performance characteristic on Al/SiC metal matrix composite using grey-fuzzy logic algorithm

PurposeThe purpose of this paper is to determine the optimum level of geometrical parameters such as helix angle, nose radius, rake angle and machining parameters such as cutting speed, feed rate and depth of cut to arrive minimum surface roughness and tool wear during end milling of Al 356/SiC metal matrix composites (MMCs) using high speed steel end mill cutter.Design/methodology/approachL27 Taguchi orthogonal design with six factors and three levels is employed for conducting experiments. Analysis of variance (ANOVA) is carried out using Minitab16 software to find the influence of each input parameter on output performance measure. Grey-fuzzy logic multi optimisation algorithm is used to find the optimum level of the input parameters for minimum surface roughness and tool wear simultaneously.FindingsIt is found that optimal combination of helix angle 40°, nose radius 0.8 mm, rake angle 12°, cutting speed 90 m/min, feed rate 0.04 mm/rev and depth of cut 1.5 mm have generated minimum surface roughness of 0.4063 µm and tool wear of 0.0375 mm. From ANOVA analysis, it is found that cutting speed influence is more on output performance followed by helix angle and rake angle compared with other machining and geometrical parameters.Originality/valueThe influence of tool geometry during end milling of MMC using Grey-fuzzy logic algorithm has not been explored previously.

The influence of tool geometry on the course of flanges radial extrusion in hollow parts

In this paper the different methods of hollow parts with flange manufacturing are presented. The results of theoretical–experimental research on radial extrusion of hollow parts with flanges are shown. In the research the pipe parts form 6060 aluminum alloy formed in ambient temperature were used. The influence of tool geometry in forming zone was investigated. Experimental research was made in special equipment placed into workspace of laboratory testing machine. Numerical simulations were made by means of Deform-3D software. In the results, the distributions of stress, strains, Cockroft–Latham criterion and loads are presented.

Performance enhancement of cryogenic machining and its effect on tool wear during turning of Al-Ticp composites

ABSTRACTThe current research is to focus on developing a liquid nitrogen diffusion system to optimize the usage of liquid nitrogen and maximizing cooling and lubrication capability by effective penetration. An atomized liquid nitrogen spray system was developed to diffuse liquid nitrogen effectively at a low flow rate (10–12 L/h) and as a high velocity (8–50 m/s) droplet jet to the machining zone. Using coated carbide tool with varying tool geometry (rake angle, approach angle, and nose radius), an investigation was performed to study the role of atomized liquid nitrogen spray-assisted machining, on performance of tool and surface quality of the machined workpiece during turning of Al-TiCp composite. To analyze the performance of liquid nitrogen spray-assisted machining, various experiments were conducted. The results obtained from the experiments reveal that the effective use of atomized liquid nitrogen spray machining is a feasible alternative to dry, wet, and cryogenically chilled argon gas. This technique significantly reduces heat generation in machining zone. The study also emphasizes the influence of tool geometry on the machinability of Al-TiCp metal matrix composites.

Simulation and Experimental Research on the Influence of Tool Geometries on the Cutting Force of High Temperature Alloy

Simulation and Experimental Research on the Influence of Tool Geometries on the Cutting Force of High Temperature Alloy

The Influence of Tool Geometry on the Mechanical Behaviour of FSSWed Al/Cu ARBed Composite

In the present study, the threaded cylindrical pin and the triangular pin were employed to friction stir spot welding of Al/Cu ARBed composite, and their influence on the material flow and mechanical properties of the spot welds were investigated. Under the same processing condition, higher temperature was measured during friction stir spot welding by using the cylindrical pin, as a result of higher frictional heat and greater material pressed by the pin face, leading to a greater area (volume) and effective length of the stir zone. This, in turn governed by the material flow, resulted in higher shear failure load of the spot welds produced by using cylindrical pin. Nevertheless, asymmetric geometry of the triangular pin appeared to cause higher microhardness around the triangular pin.

The Influence of Tool Geometry towards Cutting Performance in Machining Aluminium 7075

Aerospace industries often use Computer Numerical Control (CNC) machining in manufacturing aerospace parts. Aluminium 7075 is the most common material used as aircraft components. This research aims to produce end mill with optimum geometry in terms of the helix angle, primary radial relief angle and secondary relief angle. End mills with different geometry parameters are tested on Aluminium 7075 and data on surface roughness and tool wear were collected. The results were then analysed to determine which parameters brought the optimum result with regards to surface roughness and tool wear.

Influence of tool shoulder geometry on microstructure and mechanical properties of friction stir welded 2014-T6 Aluminium Alloy

The objective of this present work is to investigate the influence of tool geometry on mechanical properties of friction stir welded AA 2014-T6 6mm, thickness plates. In this investigation an attempt is being made to understand the effect of tool traverse speed and tool pin profile at constant tool rotational speed, with varying concave shoulder radius of R2.5, R3 & R3.5 of a straight cylindrical pin on Aluminium Alloy weldments. From the investigation it was found that the joints made by concave shoulder with radius R2.5 resulted in better mechanical properties compared to concave shoulder with radius R3 and R3.5.The microstructure is examined by using optical microscope. Joints made with concave shoulder of radius R2.5 showed finer grains compared to other tool shoulder geometry. The observed mechanical properties were correlated with their microstructures and fracture features.

The influence of turning parameters on surface integrity of nickel alloy 625

Nickel-based alloys are used in industrial sectors where high mechanical strength and corrosion resistance are required at high temperatures. However, these alloys have low machinability as a consequence of inherent properties. Some of these properties such as high cold work hardening rate and low heat conductivity may cause damages to the machined surface. Among the nickel-based alloys, one that has good properties for oil exploration is alloy 625. As the components made of this alloy are frequently used in very rough environments, this study sought to evaluate the influence of tool geometry, cutting conditions (feed and cutting speed) and tool condition (fresh or worn) on the surface integrity of turned alloy 625 parts in order to discover turning practices for this alloy that result in minimal damage to the workpiece surface. A secondary aim was to evaluate how these input variables affected the life of the coated carbide tools used in the turning experiments with this alloy. The main conclusions are that (a) the surfaces produced with a fresh tool with positive geometry had compressive residual stresses, while those produced with negative tool geometry had tensile residual stresses and (b) when a worn tool was used all the surfaces produced had compressive residual stresses.

Friction Stir Welding of Copper Alloy CuETP

Experimental researches that were performed in order to determine the mechanical parameters in the process of joining of materials using the FSW process are presented in this paper. The paper presents the joining of CuETP sheet copper alloy, with thickness of 5 mm, and provides details of the friction stir welding process. Besides that, the influence of tool geometry and the regime of welding on the quality of welded joints, was investigated. Experimental studies are made on the basis of the adopted multifactoral orthogonal plan, with varying of factors on two levels and repetition in the central point of the plan. Parameters varied in the experiment were: welding speed, rotation speed of tool, angle of pin slope, pin diameter and shoulder diameter. The family of tools is provided, based on the adopted geometric parameters. The experiment was carried out in a laboratory at ambient temperature in conditions similar to those in the production. In order to determine the quality of welded joints, mechanical tests were performed in the paper, and tensile strength and impact toughness were determined.

Prediction of cutting forces in slotting of multidirectional CFRP laminate

This paper focuses on experimental study of slotting of carbon fiber reinforced plastic (CFRP) laminate (G803/914) with three micrograin carbide knurled tools: fine, medium, and coarse toothings. It highlights the influence of tool geometry and cutting conditions (cutting speed and feed per tooth) on cutting forces and presents the damage that occurs to the composite material in response to mechanical effects. The experiment is made on CNC machine with cutting speed ranging from 80 to 200 m/min and feed per tooth from 0.008 to 0.060 mm/rev/tooth. The data was analyzed in order to establish empirical models showing the dependence of cutting forces on tool geometry and cutting conditions. The results illustrate that feed per tooth is the cutting parameter that presents the highest statistical and physical influence on cutting forces and that knurled tool fine toothings is the suitable tool that produces the least damage to the composite plate.