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Using HSM technology in machining of thin-walled aircraft structures

Bałon Paweł, Rejman Edward, Kiełbasa Bartłomiej, Smusz Robert

Acta Mechanica et Automatica

2022

Vol. 16, no. 1

27--33

Subtracting manufacturing technologies have entered that realm of production possibilities which, even a few years ago, could not be directly adapted to direct production conditions. The current machines, i.e. heavy, rigid cutting machines using high spindle speed and high feed speed, allow for manufacturing very thin and relatively long parts for use in the automotive or aerospace industry. In addition, the introduction and implementation of new 70XX aluminium alloys with high strength parameters, as well as monolithic diamond cutting tools for special machining, have had a significant impact on the introduction of high-speed machining (HSM) technologies. The main ad-vantage of the applied manufacturing method is obtaining a very good smoothness and surface roughness, reaching even Sz = 6–10 μm and Sa <3 μm, and about four times faster and more efficient machining compared to conventional machining (for the beam part). Moreover, fixed and repeatable milling process of the HSM method, reduction of operational control, easy assembly of components and increase in the finishing efficiency compared to other methods of plastic processing (forming) are other benefits. The authors present a method using HSM for the manufacturing of aircraft parts, such as the chassis beam at the front of a commuter aircraft. The chassis beam assembly is made of two parts, front and rear, which – through a bolted connection – form a complete element replacing the previous part made using traditional technology, i.e., cavity machining, bending and plastic forming. The implementation of HSM technology eliminates many operations related to the construction of components, assembling the components (riveting) and additional controls during construc-tion and assembly.

Evaluation of the effectiveness of the shot peening process for thin-walled parts based on the diameter of impressions produced by the impact of shot media

Zaleski K., Bławucki S.

Advances in Science and Technology. Research Journal

2015

Vol. 9, nr 26

77--82

The paper presents the results of studies on the effectiveness of the shot peening process for thin-walled parts based on the diameter of impressions produced by the impact of shot media. It is also described the current applications of this treatment for the thin-walled parts. The authors described an innovative measuring device which was used in the research. The material used in the studies was non-alloy steel C45. The relationships between beads diameter and thickness of workpieces on diameter of impression were presented.