Search results for "Machining"
showing 10 items of 180 documents
Process mechanics in Friction Stir Extrusion of magnesium alloys chips through experiments and numerical simulation
2017
Abstract Friction Stir Extrusion (FSE) is a novel process designed to directly recycle machining chips. An experimental campaign was carried out on AZ31 milling chips using variations in extrusion ratio, force and tool rotation rate. The process mechanics were studied and correlated to the material flow, which was elucidated through use of a copper marker. A 3D, Lagrangian, thermo-mechanically coupled dedicated numerical model was set up and validated through temperature measurements. The combination of experimental and numerical results permitted to reconstruct the complex 3D material flow induced by tool rotation and plunge into the extrusion billet chamber.
A comparative assessment of energy demand and life cycle costs for additive- and subtractive-based manufacturing approaches
2020
Abstract The applicability domain of Additive Manufacturing (AM) processes, apart from technological and quality results, relies on environmental and cost performance. These aspects still need to be better understood. To this aim, comparative analyses with conventional manufacturing routes are needed. In this paper, empirical cost and energy requirement models are suggested to assess subtractive- (machining) and additive- (Electron Beam Melting) based manufacturing approaches for the production of Ti-6Al-4V components. A life-cycle perspective is adopted, and all the steps from the input material production to the post-AM processing operations and the use phase are included. The analyses ha…
The application of the random balance method in laser machining of metals
2008
International audience; Features peculiar to laser technology offer some advantages over more traditional processes, but, like all processes, it has its limitations. This article studies the limitations of laser machining of metals, and quantifies, through an experimental design method, the influence of operating parameters on productivity and on the quality of the machined surface. Three study materials were used: an aluminium alloy, stainless steel and a titanium alloy. An initial reading of the results indicates that productivity depends mainly on the frequency of the laser pulse and that the aluminium alloy behaves differently from the other two. The quality of the machined surface, jud…
Comparison of electropolishing behaviours of TSC, ALM and cast 316L stainless steel in H 3 PO 4 /H 2 SO 4
2017
Abstract In recent decades, new manufacturing processes have been developed such as Thermal Spray Coating (TSC) and Additive Layer Manufacturing (ALM), which reduce or avoid machining of parts with complex geometries. This study aims to develop an Electropolishing (EP) process for TSC and ALM 316L Stainless Steel (SS). EP is an anodic dissolution process currently used in industry to reduce surface roughness and obtain a bright and smooth finish. The EP mechanism was studied, in a mixture of H3PO4 and H2SO4, for TSC, ALM and “cast” SS in order to determine the best conditions (time, temperature, potential). Special attention was paid to surface characterization by combining several techniqu…
A numerical model for Wire integrity prediction in Friction Stir Extrusion of magnesium alloys
2017
Abstract A numerical model for the prediction of the wire quality produced by the novel direct machining chip recycling technique known as Friction Stir Extrusion (FSE) is presented. Wire microstructure and wire integrity have been predicted by embedding in the code the equations enabling the calculation of the Zener-Hollomon parameter as well as the W parameter of the Pivnik-Plata solid bonding criterion. The proposed model, developed for the AZ31 magnesium alloy using the commercial simulation package DEFORM, is 3D Lagrangian, thermo-mechanically coupled with visco-plastic material behavior. The model was first validated against experimental temperature measurements and then used to predi…
On the optimization of the cutting conditions for an improved corrosion resistance of OFHC copper
2018
International audience; Machining has a particular impact on the surface integrity and on corrosion resistance of components. In fact, material removal induces geometrical, mechanical and micro-structural modifications in the machined surface and sub-surface that alter the electrochemical behavior of the material, and so the aging process. In this study, oxygen free high conductivity copper (OFHC) has machined under orthogonal cutting conditions using uncoated cemented carbide tools. Then, the corrosion resistance in 0.1 M NaCl salt fog atmosphere of the machined samples is analyzed. Finally, the optimal cutting conditions, including the tool geometry, for an improved corrosion resistance a…
Improving surface integrity of additively manufactured GP1 stainless steel by roller burnishing
2020
Abstract Additive manufacturing can rapidly fabricate the desired components by selectively melting and solidifying feedstock, rather than conventional subtractive machining. However, the difference between the two routes in terms of surface integrity of the final component is relevant. This paper presents a strategy to control the surface characteristics of additively manufactured stainless steel by roller burnishing. In particular, process parameters have been carefully selected to improve the surface integrity of the worked material. The quality of the surface has been analyzed in terms of roughness, hardness, microstructure and residual stresses. The overall product endurance under high…
Design of continuous Friction Stir Extrusion machines for metal chip recycling: issues and difficulties
2018
Abstract Friction Stir Extrusion is an innovative direct-recycling technology developed for metal machining chips. During the process, a rotating die is plunged into a cylindrical chamber containing the material to be recycled. The stirring action of the die prompts solid bonding phenomena allowing the back extrusion of a full dense rod. One of the main weakness of this technology is the discontinuity of the process itself that limits the extrudates volume to the capacity of the chamber. In order to overcome that limitation, a dedicated extrusion fixture has to be developed, keeping into account the concurrent needs of a continuous machine. The geometry of the die has to ensure proper press…
AZ31 magnesium alloy recycling through friction stir extrusion process
2015
Friction Stir Extrusion is a novel technique for direct recycling of metal scrap. In the process, a dedicated tool produces both the heat and the pressure to compact and extrude the original raw material, i.e., machining chip, as a consolidated component. A proper fixture was used to carry out an experimental campaign on Friction Stir Extrusion of AZ31 magnesium alloy. Variable tool rotation and extrusion ratio were considered. Appearance of defects and fractures was related to either too high or too low power input. The extruded rods were investigated both from the metallurgical and mechanical points of view. Tensile strength up to 80 % of the parent material was found for the best combina…
Impact des conditions d'usinage sur la zone du matériau affectée par le procédé
2007
Colloque avec actes et comité de lecture. Internationale.; International audience; Les procédés d'usinage peuvent créer des contraintes résiduelles à la surface des pièces usinées et ainsi modifier la microstructure et la texture de la matière proche de la surface. De tels changements sont importants pour l'étude du comportement des pièces au cours du temps. Il est alors nécessaire de quantifier les contraintes résiduelles, les composantes de texture et de déterminer la microstructure induite par l'usinage pour comprendre et prédire le comportement des surfaces considérées. Dans cette étude, le matériau cuivre pur a été choisi et considéré comme un "système modèle". En tournage, l'influence…