Surface Relief Shaping by Combined Machining of Aluminum Alloys

Surface Relief Shaping by Combined Machining of Aluminum Alloys

Available online at www.sciencedirect.com ScienceDirect Procedia Engineering 150 (2016) 948 – 952 International Conference on Industrial Engineering...

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Available online at www.sciencedirect.com

ScienceDirect Procedia Engineering 150 (2016) 948 – 952

International Conference on Industrial Engineering, ICIE 2016

Surface Relief Shaping by Combined Machining of Aluminum Alloys V.E. Inozemtsev* Moscow State University of Railway Engineering, Obraztsova street, 9, Moscow 127994, Russia

Abstract The article describes the formation of surface topography in combined finishing machining. Use of combined machining can achieve a better quality of the resulting surface. Multiple studies have helped to formulate the main provisions and recommendations regarding the determination of appropriate machining parameters, selection of cutting parameters and the environmental requirements the cutting tool in use should meet. However, many questions on the quality of, and opportunities for combined shaping methods have not yet been studied. © 2016 2016The TheAuthors. Authors. Published Elsevier © Published by by Elsevier Ltd.Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of ICIE 2016. Peer-review under responsibility of the organizing committee of ICIE 2016 Keywords: aluminum; silumin; metal; finishing; surface roughness; combined treatment; quality parameters; topography; technology.

1. Main text The using of high-tech materials ensures the required level of quality engineering products. Technology for production of these materials allow to create in most cases already finished parts without additional forming operations, but for certain categories of parts required surgery finish machining. Therefore, problems associated finishing forming operations are highly relevant and required an individual approach to deal with them [1]. The high-tech materials are also silumin and other low-melting materials. Silumin used in the aviation and automotive industries. It's making pistons, crankcases and engine block. Investigation of the process of the blade machining of aluminum alloys are engaged many scientists, including experts from the University of Clemson in the International Center for Automotive Research [2]; Technological

* Corresponding author. Tel.: +7-965-254-5506; E-mail address: [email protected]

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license

(http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of ICIE 2016

doi:10.1016/j.proeng.2016.07.068

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University of North Texas Discovery Park [3] and others [4, 5]. Large range of alloys based on aluminum, the amount of which is due to the technological requirements of different levels, it points to the need to identify best practices and technological approaches to their treatment, reducing the complexity of the processes by reducing the number of operations, the reduction of the basic process time and improving product quality. Machining an aluminum-based material is accompanied bullies surface [6], emerging from the cutter, and the sticking of material to be removed at the cutting edge of the tool, which reduces the efficiency of the cutting process, heat dissipation and increased tool wear. To achieve a high surface quality when cutting silumin recommended to use special inserts with diamond-like carbon coating, and other wear-resistant coatings. In this case the tool should have a large rake angle, a small radius of rounding of the cutting edge and a small radius ȡ r top tool. To increase the heat dissipation in some cases, when the treatment is carried out thin-walled bushings, it is advisable to use coolants. The combined processing methods are mainly represented by the electrochemical treatment. Electrochemical machining has a number of advantages over mechanical and electrophysical methods of treatment, in particular, can handle any metals and alloys, regardless of their physical and chemical properties as well as make-complex parts with high accuracy as high as 0.5 mm [7 ]. At the same time, the wider application of electrochemical machining constrained by its disadvantages, which include the high cost of equipment, complexity of manufacturing an electrode-tool, restrictions on the form of parts, environmental issues and large power consumption of the process [8]. Given the advantages of electrochemical machining at the quality and accuracy of processing, which is especially important in the finishing stages of machining, currently in production are being actively implemented and combined sequential treatment methods. For example, electrical discharge machining methods in comparison with the electrochemical machining less energy intensive, demanding not to the composition and quality of the working fluid, but the surface layer of finished parts is drop forming and a crater forming structures thermally altered and deformed. A common practice is the use of electrical discharge machining methods after mechanical polishing the surface of various abrasives (silicon carbide, diamond pastes), which greatly complicates the process. In the last 1015 years in various countries, especially in Japan and the US carried out engineering and design development and industrial research to develop equipment to combine electrical discharge machining methods and electrochemical machining to use the positive aspects of each individual process [9]. The various processes are also the use of the methods of the anode-machining, electrochemical grinding and polishing after the mechanical, thermal and electrophysical processing. Increase productivity and quality of processing is also achieved in the multi-process using an abrasive machining [10]. In all cases, the combined machining on the same production equipment allows to realize the benefits of the electrochemical machining, while reducing the time and energy intensity of the process. The finishing anode-mechanical treatment is recommended to carry electric current at low densities, so the main value when it is executed are the mechanisms of anodic dissolution and mechanical removal of the film by moving tool. These processes occur mainly on the tops of the microscopic irregularities, which are subject to the most intense electrochemical exposure and only for them there is a continuous mechanical removal of the film. In the hollows of microscopic irregularities formed a thick layer of film, play a protective role. Taken together, this leads to a continuous reduction in roughness, achieving high precision and surface finish [14]. The microrelief researching for aluminum surface after the combined anode-machining performed under different conditions showed a tendency to change the surface characteristics in the time with little change in impact plating processes at the same current and voltage conditions. In the study examined the combination of mechanical and anodic treatment. The mill with three teeth made of hard alloy T15K6 (mechanical milling) is used as a cutting tool. The cutting fluid was applied as a 12% aqueous solution of aluminum sulfate Al2(SO4)3, in all cases the current and voltage in the range conform I = 0.4-0.6 A; U = 10-18 V. Here were examined a few samples after different variants of formation: x A sample which has passed milling (n=1600 rev/min, t=0.5 mm) and subsequently subjected to a galvanic treatment (I=0.4 A, U=10 V) in a solution of 12% Al2(SO4)3 for 10 minutes ; x A sample which has passed milling (n=1600 rev/min, t=0.5 mm); x A sample which has passed the anode-machining (I=0.6 A, U=18 V) 12% solution of Al2(SO4)3 (n=1600 rev/min, t=0.5 mm);

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x A sample which has passed the anode-machining (I=0.6 A, U=18 V) in a solution of 12% Al2(SO4)3 (n=1600 rev/min, t=0.5 mm) delayed galvanic process 2 minutes. As the results, the lowest surface roughness is observed at the sample-held machining anode (I=0.6 A, U=18 V) in a solution of 12% Al2(SO4)3 (n=1600 rev/min, t=0.5 mm) and is approximately Sa 21,0549 micrometers (Fig.1.a). The surface profiles obtained after the processing of each of the methods presented above, are shown in Figure 2.

Fig. 1. Aluminum A2 surface after the anode-machining (x1000). a) anode-mechanical treatment; b) galvanic treatment.

As it should from the photos in Fig. 1, on an area of 100 mkm after the galvanic surface treatment characterized by the predominance of the projections (light areas) and troughs (dark area). Thus, by using only a mechanical treatment of the surface relief formation due to the action of the cutting edge of the tool, taking into account the presence of factors and coolants. When a galvanic surface treatment process with an exposure for time 10 minutes (in this case the surface was pre-treated with cutter n = 1600 rev/min, t = 0.5 mm) relief is formed largely at the expense of extended flow time in the anodizing process and destruction the relief surface formed by the blade tool. At the same time for the duration of the anodic process the surface relief can not reach smoothing irregularities, since uniformity of the destruction of the surface will change due to the increase in the difference between the oxide film thickness on the uneven tops and in the valleys. Use of anode-machining results in a relatively short duration electroplating process when oxides in an electrochemical reaction does not have time to form local areas protected from destruction. Comparison of surface profiles after various methods of forming the surface shows that the anode-mechanical action on the surface of the most effective in terms of reducing the roughness (Fig.2.c).

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Fig. 2. The surface proflles after machining. a) the sample after milling (n = 1600 rev / min, t = 0,5 mm) and subsequently subjected to a galvanic treatment (I = 0.4 A, U = 10 V) in a solution of 12% Al2 (SO4) 3 for 10 minutes; b) the sample after milling (n = 1600 rev / min, t = 0,5 mm); c) the sample which has passed the anode-machining (I = 0,6 A, U = 18 V) in a solution of 12% Al2 (SO4) 3 (n = milling at 1600 rev / min, t = 0,5 mm); d) the sample, past the anode-mechanical treatment (I = 0,6 A, U = 18 V) in a solution of 12% Al2 (SO4) 3 (n = milling at 1600 rev / min, t = 0,5 mm) delayed electroplating processes in 2 minutes.

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2. Conclusion The use of this complex consisting of machining and electrochemical activation SOTS allows virtually get low the surface roughness that is the corresponding technical requirements of quality products. The electro-chemical combined machining method allows to control quality parameters in the process of forming the surface as a result of contributing to the achievement for the required level of quality parameters of the surface layer, including specific indicators of quality that are decisive for the particular category of difficult to machine materials. The combination of the anode and the mechanical action under optimal processing conditions more effectively than separate use of these methods of formation and more efficient processing. References [1] M.Yu. Kulikov, V.E. Inozemtsev, Technological method for the finishing process of fusible alloy Precision Machining VII, in: Proceeding of Selected peer reviewed papers from the 7th International Congress of Precision Machining (ICPM 2013). (2013) 224௅228. [2] S.S. Cypress, G.A. Libenson, Powder metallurgy, Metals, Moscow, 1980. [3] M.Yu. Kulikov, V.E. Inozemtsev, A method of improving the quality of the surface layer by using a combination of mechanicalelektrohimiicheskoy processing, in: Collection of scientific papers Visoki tenologii in mashinobuduvanni, Kharkiv Polytechnic Institute, 2012, pp. 168௅170. [4] V.E. Inozemtsev, Cermet processing, in: Proceedings of the international scientific-practical conference Fundamental problems of modern technology in mechanical engineering. (2010). [5] Information on http://minds.wisconsin.edu/bitstream/handle/ 1793/65377/0064-1.pdf?sequence=1. [6] Information on http://bookr2.com/viewmanual/197514. [7] A.N. Zaytsev, Precision electrochemical copying-broaching machines of new generation, Economy and production. 1 (2002) 38௅41. [8] V.V. Glebov, S.V. Kirsanov, The combined electrochemical methods of processing details, Basic Research. 1 (2006) 73௅74. [9] H. Ramasawmy, L. Blunt, 3D surface topography assessment of the effect of different electrolytes during electrochemical polishing of EDM surfaces, International Journal of Machine Tools and Manufacture. 5 (2002) 567௅574. [10] J. Kozak, K.E. Oczos, Selected problems of abrasive hybrid machining, Journal of Materials Processing Technology. 3 (2001) 360௅366. [11] I.M. Kovensky, V.N. Kuskov, N.N. Prokhorov, Structural transformations in metals and alloys in electrolytic exposure, GNGU, Tyumen, 2001. [12] V.M. Beletsky, G.A. Krivov, The aluminium alloys (composition, properties, technology, applications), Directory, Kominteh, Kiev, 2005. [13] B.N. Babich, E.V.Vershinin,V.A. Glebov, The metal powders and powder materials, Directory, Ecomet, Moscow, 2005. [14] Information on http://www.clemson.edu/manufacturing- lab/ documents/publications/kuttolamadom%25202010b.pdf. [15] Information on http://www.ijastnet.com/journals/Vol_2_No_1_January_2012/13.pdf. [16] M.Yu. Kulikov, V.E. Inozemtsev, The investigation of the impact of cutting conditions on the quality of the formation of metal products surface finish when turning, The world of transport. 2 (2012) 44௅49. [17] V.E. Inozemtsev, The using and processing of sintered metal, The world of transport. 4 (2010) 44௅48. [18] A.N. Afonin, E.V. Gaponenko, O.Yu. Erenkov, Advanced engineering technology, Spectr, Moscow, 2012. [19] V.N. Poduraev, The cutting of hard materials, Higher School, Moscow, 1974. [20] V.E. Inozemtsev, The factors influencing the technological capabilities of sintered metal-ceramic materials, in the process of finishing machining, Scientific - Technical Journal Fundamental and applied problems of engineering and technology. 288 (2011) 61௅66. [21] V.E. Inozemtsev, M.Yu. Kulikov, The research of influence of conditions of finish machining sintered cermet material formed by the quality of the surface, Interuniversity collection of scientific papers of Ivanovo State University: Physics, chemistry and mechanics of tribosystems. (2011) 88௅93.