scholarly journals Milling of an Aluminium Matrix Composite Using MCD-Tipped Tools with Adjusted Corner and Minor Cutting Edge Geometries

2021 ◽  
Vol 5 (9) ◽  
pp. 235
Author(s):  
Benjamin Clauß ◽  
Andreas Schubert
Keyword(s):  
Residual Stresses ◽  
Lightweight Design ◽  
Stable Process ◽  
Cutting Edge ◽  
Aluminium Matrix ◽  
Experimental Investigations ◽  
Process Conditions ◽  
Diamond Cutting ◽  
Aluminium Matrix Composite ◽  
Compressive Residual Stresses

Aluminium matrix composites (AMCs) represent suitable materials for lightweight design applications. The abrasive ceramic reinforcements typically require diamond cutting materials to prevent excessive tool wear. In milling with diamond cutting materials the influence of cutting parameters was already examined to a significant extent. Investigations concerning the effect of modified tool geometries are limited and the potentials with regard to the geometrical and physical surface properties are unclear. Accordingly, experimental investigations in milling of a 10 vol.% SiC particle-reinforced aluminium wrought alloy EN AW-2017 T4 were addressed. The effect of modified corner and minor cutting edge geometries were investigated based on mono crystalline diamond (MCD)-tipped tools to benefit stable process conditions. The results indicated achievable areal roughness values in the range around 0.2μm. Especially the application of the lowest cutting edge angle and a trailing minor cutting edge led to strong fluctuations of the surface parameters. The lowest valley void volumes were achieved with an arched minor cutting edge. Generally, finish machining led to stronger compressive residual stresses compared to the state prior to machining. The strongest increase was achieved using a corner radius combined with a straight minor cutting edge. It is concluded that reduced effective radii generating the surface enable an acceptable surface structure and strong compressive residual stresses and should be addressed in further investigations.

Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel

1999 ◽  
Vol 122 (4) ◽  
pp. 642-649 ◽  
Author(s):  
Jeffrey D. Thiele ◽  
Shreyes N. Melkote ◽  
Roberta A. Peascoe ◽  
Thomas R. Watkins
Keyword(s):  
Residual Stresses ◽  
Hard Turning ◽  
Cutting Edge ◽  
Edge Geometry ◽  
Surface Residual Stresses ◽  
Aisi 52100 ◽  
Aisi 52100 Steel ◽  
Finish Hard Turning ◽  
Hardness Values ◽  
Compressive Residual Stresses

An experimental investigation was conducted to determine the effects of tool cutting-edge geometry (edge preparation) and workpiece hardness on surface residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with representative types of edge geometry including “up-sharp” edges, edge hones, and chamfers were used as the cutting tools in this study. This study shows that tool edge geometry is highly influential with respect to surface residual stresses, which were measured using x-ray diffraction. In general, compressive surface residual stresses in the axial and circumferential directions were generated by large edge hone tools in longitudinal turning operations. Residual stresses in the axial and circumferential directions generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools. Microstructural analysis shows that thermally-induced phase transformation effects are present at all feeds and workpiece hardness values with the large edge hone tools, and only at high feeds and hardness values with the small edge hone tools. In general, continuous white layers on the workpiece surface correlate with compressive residual stresses, while over-tempered regions correlate with tensile or compressive residual stresses depending on the workpiece hardness. [S1087-1357(00)00304-X]

Residual Stresses Generated by the Combined Burnishing - Cutting Process in the Worked Parts

2014 ◽  
Vol 657 ◽  
pp. 103-107 ◽  
Author(s):  
Gheorghe Brabie ◽  
Gheorghe Mustea ◽  
Bogdan Chirita
Keyword(s):  
Magnesium Alloy ◽  
Residual Stresses ◽  
Experimental Determination ◽  
Experimental Investigations ◽  
Machined Surface ◽  
Combined Process ◽  
Part Surface ◽  
Working Parameters ◽  
Compressive Residual Stresses

The cutting followed by burnishing, used like a combined process, leads to the improvement of the part surface quality (roughness, hardness, microstructure etc.) and to reduction of the costs and manufacturing times as a function of different working parameters. One of the factors and parameters that characterize the machined surface by this combined process is the residual stresses that are generated and located in the part deformed strata. The present paper analyses the results concerning the experimental determination of the residual stresses generated in the machined surfaces of parts made from magnesium alloy by the burnishing - turning combined process. The experimental investigations have shown that in the machined strata the combined process determines the occurrence of the compressive residual stresses and hence the fatigue and cracking resistances of the machined materials will be improved.

Analysis of residual stresses in main crankshaft bearings after induction surface hardening and finish grinding

2003 ◽  
Vol 217 (3) ◽  
pp. 173-182 ◽  
Author(s):  
J Grum
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Subsurface Layer ◽  
Physical And Mechanical Properties ◽  
Fatigue Cracking ◽  
Correct Selection ◽  
Grinding Wheel ◽  
Process Conditions ◽  
Workpiece Material ◽  
Compressive Residual Stresses

The exact pattern of residual stresses will depend on the heat treatment temperatures employed, the depth of hardening and the type of quenchant. Process conditions that give rise to compressive residual stresses on the surface of heat-treated components are favourable. This type of residual stress delays the initiation of fatigue cracking in service, which typically occurs on the surface of the part under the action of cyclic tensile stresses. The last phase in the manufacturing of crankshafts is finish grinding in order to achieve the desirable condition of the surface and the subsurface layer, i.e. suitable dimensions, suitable surface roughness and the corresponding distribution of relative grinding residual stress in the subsurface have to be ensured. By correct selection of the grinding wheel and grinding conditions, taking into account the physical and mechanical properties of the workpiece material, the very favourable compressive residual stresses in the hardened surface layer will be retained after grinding.

scholarly journals Residual stresses in shape memory alloy fiber reinforced aluminium matrix composite

2017 ◽  
Vol 165 ◽  
pp. 012002
Author(s):  
Tang Tsz Loong ◽  
Saifulnizan Jamian ◽  
Al Emran Ismail ◽  
Nik Hisyammudin Muhd Nur ◽  
Yoshimi Watanabe
Keyword(s):  
Shape Memory Alloy ◽  
Residual Stresses ◽  
Shape Memory ◽  
Matrix Composite ◽  
Aluminium Matrix ◽  
Fiber Reinforced ◽  
Aluminium Matrix Composite

Introducing Residual Stresses on Sheet Metals by Slide Hardening under Stress Superposition

2021 ◽  
Vol 883 ◽  
pp. 143-150
Author(s):  
Jonas Lehmann ◽  
Hui Chen ◽  
Moritz Kruse ◽  
Noomane Ben Khalifa
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Sheet Metal ◽  
Experimental Investigations ◽  
Flat Specimen ◽  
Sheet Metal Parts ◽  
Hardening Process ◽  
Stress Superposition ◽  
Compressive Residual Stresses ◽  
Mechanical Surface

The fatigue strength and product life of the components can be improved by introducing compressive residual stresses using mechanical surface treatment. Appling stress superposition is an option to be used in metal forming to reduce the process force. In this work experimental investigations to analyze the influence of stress superposition on residual stresses of sheet metal parts by a slide hardening process were carried out. The flat and elastically pre-bended specimens (i.e. stress-superimposed specimen) were processed with a slide diamond tool under different loading forces. The residual stress generated through the thickness of the sheet metal was similar for the flat and the pre-bended specimens. The superimposed stress by elastic bending of the sheet metal led to higher compressive residual stress compared to the flat specimen under the same loading force. Nevertheless, the contour of the pre-bended specimen showed more bulking compared to the flat specimen. The mechanical characteristics determined by hardness measurements showed no significant improvement when applying stress superposition.

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