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1

Analysis and prediction of the impact of technological parameters on cutting force components in rough milling of AZ31 magnesium alloy

Kulisz M., Zagórski I., Weremczuk A., Rusinek R., Korpysa J.

Archives of Civil and Mechanical Engineering

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2022

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Vol. 22, no. 1

art. no. e1, 2022

EN

This paper presents the results of experimental study of the AZ31 magnesium alloy milling process. Dry milling was carried out under high-speed machining conditions. First, a stability lobe diagram was determined using CutPro software. Next, experimental studies were carried out to verify the stability lobe diagram. The tests were carried out for different feed per tooth and cutting speed values using two types of tools. During the experimental investigations, cutting forces in three directions were recorded. The obtained time series were subjected to general analysis and analysis using composite multiscale entropy. Modelling and prediction were performed using Statistica Neural Network software, in which two types of neural networks were applied: multi-layered perceptron and radial basis function. It was observed that milling with high cutting speed values allows for component values of cutting force to be lowered as a result of the transition into the high-speed machining conditions range. In most cases, the highest values for the analysed parameters were recorded for the component Fx, whereas the lowest were recorded for Fy. Additionally, the paper shows that a prediction (with the use of artificial neural networks) of the components of cutting force can be made, both for the amplitudes of components of cutting force Famp and for root mean square Frms.

2

Surface Quality in Milling of AZ91D Magnesium Alloy

Zagórski Ireneusz, Korpysa Jarosław

Advances in Science and Technology. Research Journal

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2019

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Vol. 13, no 2

119--129

EN

This paper is an attempt at determining the effect of technological parameters of milling on the surface roughness of the AZ91D magnesium alloy. The cutting tool used in tests was a TiAlN-coated carbide milling cutter. The milling tests were carried out at variable cutting speed, feed per tooth and depth of cut, and the results were compared. The analysis was based on the 2D roughness parameters measured on the end and lateral faces of specimens, as well as on the 3D roughness parameters measured on the end faces of specimens. The test results indicated that the increase in the feed per tooth results in the increase in the value of 2D and 3D surface roughness parameters. It was found that cutting speed and axial depth of cut have a negligible effect on the 2D roughness of the workpiece surface, whereas the increase in cutting speed results in the reduction of the 3D surface roughness parameters.

3

Artificial neural network modelling of vibration in the milling of AZ91D alloy

Zagórski I., Kulisz M., Semeniuk A., Malec A.

Advances in Science and Technology. Research Journal

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2017

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Vol. 11, no 3

261--269

EN

The paper reports the results of artificial neural network modelling of vibration in a milling process of magnesium alloy AZ91D by a TiAlN-coated carbide tool. Vibrations in machining processes are regarded as an additional, absolute machinability index. The modelling was performed using the so-called “black box” model. The best fit was determined for the input and output data obtained from the machining process. The simulations were performed by the Statistica software using two types of neural networks: RBF (Radial Basis Function) and MLP (Multi-Layered Perceptron).

4

Analysis of chip fragmentation in AZ91HP alloy milling with respect to reducing the risk of chip ignition

Gziut O., Kuczmaszewski J., Zagórski I.

Eksploatacja i Niezawodność

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2016

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Vol. 18, no. 1

73--79

EN

Magnesium alloys are used as advanced structural materials for producing machine components for the aircraft or automotive industry. The machining of these components involves the risk of uncontrolled ignition during machining operations and production of fine-grained chip fractions causing the wear of kinematic pairs in technological machines. Given the operation of machine tools, the determination of a method for assessing risk based on determining a safe milling range and suitable operational parameters seems justified. The paper presents the results of investigations on chip fragmentation, chip mass and dimensions. Based on these parameters, we determine effective and safe regions with respect to operation of machine tools. The experiments are performed on magnesium alloy AZ91HP, one of the most widely used casting alloys.

PL

Stopy magnezu są wykorzystywane jako nowoczesne materiały konstrukcyjne na elementy maszyn wytwarzane m.in. na potrzeby przemysłu lotniczego czy motoryzacyjnego. Obróbka skrawaniem tych elementów wiąże się z ryzykiem niekontrolowanego zapłonu podczas wykonywania operacji obróbkowych oraz powstawaniem drobnoziarnistych frakcji wiórów powodujących przyspieszone zużycie węzłów kinematycznych maszyn technologicznych. Zaproponowanie oceny ryzyka związanego z wyborem zakresu, uznawanego za bezpieczny, parametrów technologicznych frezowania, wydaje się celowe ze względów eksploatacyjnych maszyn obróbkowych. W artykule przedstawiono wyniki badań fragmentacji wiórów, ich masy oraz wymiarów charakterystycznych wiórów. Istotnym wydaje się określenie (na podstawie wymienionych wskaźników) obszarów uznawanych ze efektywne a zarazem bezpieczne z punktu widzenia eksploatacji maszyn obróbkowych. Do badań wytypowano często stosowany stop magnezu, z grupy odlewniczych, AZ91HP.

5

Study of chip ignition and chip morphology after milling of magnesium alloys

Zagórski I., Kuczmaszewski J.

Advances in Science and Technology. Research Journal

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2016

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Vol. 10, nr 32

101--108

EN

The paper analyses the impact of specified technological parameters of milling (vc , fz, ap ) on time to ignition. Stages leading to chip ignition were analysed. Metallographic images of magnesium chip were presented. No significant difference was observed in time to ignition in different chip fractions. Moreover, the surface of chips was free of products of ignition and signs of strong oxidation.

6

Impact of depth of cut on chip formation in az91hp magnesium alloy milling with tools of varying cutting edge geometry

Gziut O., Kuczmaszewski J., Zagórski I.

Advances in Science and Technology. Research Journal

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2015

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Vol. 9, nr 26

49--56

EN

Safety of Mg milling processes can be expressed by means of the form and the number of fractions of chips formed during milling. This paper presents the state of the art of magnesium alloys milling technology in the aspect of chip fragmentation. Further-more, the impact of the depth of cut ap and the rake angle γ on the number of chip fractions was analysed in the study. These were conducted on AZ91HP magnesium cast alloy and milling was performed with carbide tools of varying rake angle values (γ = 5º and γ = 30º). It was observed that less intense chip fragmentation occurs with decreasing depth of cut ap. The number of chip fractions was lower at the tool rake angle of γ = 30º. The test results were formulated as technological recommendations according to the number of generated chip fractions.

7

The influence of technological parameters and geometric features of a cutting edge on cutting forces during AZ91HP alloy milling

Gziut O., Kuczmaszewski J., Zagórski I.

Advances in Manufacturing Science and Technology

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2014

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Vol. 38, nr 2

83--92

EN

This article presents the state of knowledge on cutting forces during the milling of light alloys. Research results presented in the paper concern cutting forces and their amplitudes depending on the technological parameters (vc, fz, ap) with the use of two carbide milling cutters having a different cutting edge geometry (γ=5º and γ=30º). Research and analysis of cutting forces appear to be a significant factor determining chip deformation, temperature and cutting area strain, among others. Lower values of cutting force components are observed in the case of γ=30º tool processing. For the purpose of this research casting magnesium alloy AZ91HP was selected.

PL

W pracy wykonano analizę ogólnego stanu wiedzy dotyczącą sił skrawania podczas frezowania stopów lekkich. Przedstawiono wyniki pomiarów sił skrawania w zależności od zmiany określonych parametrów technologicznych (vc, fz, ap) przy zastosowaniu dwóch frezów węglikowych o zmiennej geometrii ostrza (γ=5º i γ=30º). Ustalono, że wartości sił skrawania są czynnikiem determinującym m.in. odkształcanie się wióra, temperaturę oraz odkształcenia materiału warstwy wierzchniej w strefie skrawania. Mniejsze wartości składowych sił skrawania stwierdzono dla obróbki narzędziem o kącie γ=30º. Proces obróbki prowadzono dla stopu magnezu AZ91HP.

8

Badania mikrotwardości stopów magnezu po szybkościowym frezowaniu na sucho

Zagórski I., Kuczmaszewski J.

Mechanik

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2013

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R. 86, nr 8-9

720--722, 724

PL

Stopy magnezu są często wykorzystywane na elementy maszyn, zwłaszcza przez przedsiębiorstwa branży lotniczej. Produkcja nowoczesnych elementów lotniczych związana jest z efektywną obróbką szybkościową. Wydajne frezowanie może prowadzić do zmian właściwości fizycznych warstwy wierzchniej. Głównym celem badań była analiza wpływu parametrów technologicznych frezowania na mikrotwardość.

EN

Magnesium alloys are commonly used for manufacturing various components, in particular by companies in the aerospace industry. Modern aerospace components production is largely related to efficient high-speed machining. Efficient milling can result in changing physical properties of the surface layer. The aim of the study was to analyse the correlation between technological parameters of milling operations and the surface layer microhardness.

9

The study of cutting forces and their amplitudes during high-speed dry milling magnesium alloys

Zagórski I., Kuczmaszewski J.

Advances in Science and Technology. Research Journal

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2013

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Vol. 7, nr 20

61--66

EN

This paper presents the state of knowledge on cutting forces values during milling of different magnesium alloy types. Additionally, the results of own research on cutting forces and their amplitudes after milling magnesium alloys used for manufacturing elements applied in the aerospace industry are included. The subject of the analysis was the influence of technological parameters and the tool type on cutting forces and their amplitudes. The analysis is important due to the correlation between cutting forces and temperature in the cutting area, and, consequently, the safety of machining and strain of the workpiece.