Experimental Study for Improving the Repair of Magnesium–Aluminium Hybrid Parts by Turning Processes
Abstract
:1. Introduction
2. Methodology
- ▪
- Pre-experimental planning. Factors, levels, ranges, and response variables are set up.
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- Selection of the experimental design. At this stage, the most adequate design of experiments (DOE) is selected according to the available resources and the objectives fixed in the study. In this case, the goal is to analyze the variability of the surface roughness of hybrid parts with a UNS M11917 magnesium alloy base and with two UNS A92024 aluminium alloy inserts obtained by turning. The surface roughness has been chosen as a response variable and, specifically, the arithmetic mean deviation of the assessed profile, Ra, because it is one of the most widely used variables in the literature and it allows for a better comparison with other studies on this theme. The process is to be performed with different types of tools, different cutting conditions, and under dry conditions, so that the potential influential factors to include in the design have been identified as: depth of cut, d; feed rate, f; spindle speed, S; and type of tool, T. In addition, the Ra values are taken on different zones of the workpieces, since previous studies [47,48,49,50,51,52,53] have found that the location where the surface roughness measurement was taken seemed to influence the value of the surface roughness. Now, there are two positions where the response variable is measured in the specimen: the location with respect to the specimen, LRS, and the position where the response variable is measured with respect to the insert, LRI. Their levels are fixed, taking into account the following criteria:
- -
- First, the work is framed within a study involving other types of hybrid parts based on magnesium, but using different types of materials for the inserts used. Then, it seems reasonable to try, at least, two types of tools: one that is suitable for magnesium and other non-ferrous alloys, and another for other types of materials. Thus, it could be known how these tools behave with these materials and with others separately, to see if they can then be used in applications involving all types of materials. That is, two levels should be established for the factor, type of tool, T.
- -
- Second, as the study deals with repair and maintenance operations, in general, the depth of cut, d, has to be as small as the available machines allow, since, otherwise, the parts could be out of dimensional tolerances. Then, one level is enough.
- -
- Third, for the factors feed rate, f, and spindle speed, S, which are expected to have influences on the study (in particular the feed rate), two levels for each one are fixed.
- -
- Finally, as has been mentioned above, previous studies seem to indicate that the roughness can vary with the length of machining of the piece. Therefore, LRS and LRI are going to be taken into account as influencing factors. Specifically, two levels for LRS and three levels for LRI will be established. That is, surface roughness measurements will be taken: for LRS, following the feeding direction, at the beginning of the specimen, LRS1, and at the end of the specimen, LRS2; and for LRI, according to the turning direction, before the insert, LRI1, in the insert, LRI2, and after the insert, LRI3. Table 1 shows the factors and levels fixed for them and their designations.
- ▪
- Performing the experiment. As this work is framed within a larger project, the execution of the tests has been programmed to be carried out systematically following the next steps:
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- Previous activities to the machining process. These activities consist in preparing: the specimens of the hybrid parts, the tools, the protocols to be used to calculate the cutting parameters’ values that will be introduced into the machine, the instrument where the surface roughness measurements will be taken, and the protocols to register the obtained data.
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- Turning trials. During the trials, specimens are mechanized under the cutting conditions determined for them.
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- Monitoring processes. All of the turning trials described previously along with the obtained chips and used tools were photographed and recorded by video with a Hero Silver 4 high-resolution camera (GOPRO Inc., San Mateo, CA, USA) in order to have graphical documents that can be analysed once the process has finished.
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- Roughness measurement. Measurements of the surface roughness are made using a Mitutoyo Surftest SJ 401 surface roughness tester (Mitutoyo America Corporation, Aurora, IL, USA).
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- Statistical analysis of the data. The statistical methodology carried out in order to analyze the results of the experimental design is briefly described in [54]. The variability of the surface roughness is modelled through the analysis of variance (ANOVA) over the average roughness values, Ra, identifying the most influential factors and interactions on the surface finish. The model hypothesis is checked, and the ranking of the different combinations of the process parameters’ levels is obtained based on the roughness values predicted by the model. The optimal combination of cutting conditions (minimum expected roughness) is selected from such ranking. In addition, we conduct an exploratory data analysis to obtain a clear graphical view of the key aspects in the distribution of the influential factors on the surface finish of hybrid magnesium–aluminum parts, and relationships between pairs of influential factors have been illustrated by interaction graphs.
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- Conclusions. Some conclusions are established from the results obtained in the statistical analysis.
3. Experimental Tests
3.1. Materials
- ▪
- In the absence of standards, national or international, or any other reference in relation to the design and fabrication of test pieces of metal hybrid components, such as those presented in this work, it was decided to start the study with different simple geometries for both the base and for the inserts, since, on many occasions, the repair and maintenance operations are limited to a small area of the surface of the piece and, therefore, the geometry to be machined is reduced to simple forms, such as those proposed in the general project regardless of the overall complexity of the piece [20,45]. On the other hand, this approach would allow, if necessary, for an increase in the degree of complexity of the geometry of the test pieces from solid knowledge about the joint behaviour of the individual materials depending on the results that were obtained.
- ▪
- We have previous experience in the machining of both materials, both in continuous turning (horizontal and facing) [47,48,49,50,51,52,53,54,55,56,57,58,59,60] and in intermittent turning [56,57,58,59,60]. The geometry of the specimens raised in the present study is a natural evolution of the geometries and materials previously studied separately that have just been mentioned.
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- ▪
3.2. Cutting Tools
3.3. Cutting Conditions
3.4. Measurement Locations
3.5. Factors and Levels Selected
4. Results, Analysis, and Discussion
4.1. Results
- ▪
- In relation to the feed rate, the values of the roughness increase in the three measured zones. Specifically, for f = 0.10 mm/rev, the mean values of the roughness are RaLRI1 = 0.57 μm; RaLRI2 = 0.48 μm; and RaLRI3 = 0.57 μm, and for f = 0.15 mm/rev, the mean values of the roughness are RaLRI1 = 0.91 μm; RaLRI2 = 0.86 μm; and RaLRI3 = 1.08 μm.
- ▪
- With respect to the spindle speed, the values of Ra decrease slightly in the magnesium base and remain equal, or slightly increase, in the aluminum insert. Specifically, for S = 925 rpm, the mean values of the roughness are RaLRI1 = 0.76 μm; RaLRI2 = 0.67 μm; and RaLRI3 = 0.86 μm. For S = 1470 rpm, the mean values of the roughness are RaLRI1 = 0.72 μm; RaLRI2 = 0.67 μm; and RaLRI3 = 0.80 μm.
4.2. Statistical Discussion
4.3. Technological Discussion
5. Conclusions
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Factors | Levels |
---|---|
Feed rate, f, (mm/rev) | f1, f2 |
Spindle speed, S, (rpm) | S1, S2 |
Type of tool, T | T1, T2 |
Depth of cut, d, (mm) | d1 |
Location with respect to the specimen, LRS | LRS1, LRS2 |
Location with respect to the insert, LRI | LRI1, LRI2, LRI3 |
T | S, (rpm) | f, (mm/rev) | LRI | LRS | Observations | |||
---|---|---|---|---|---|---|---|---|
T1 | S1 | f2 | LRI2 | LRS1 | LRS2 | 1 | ||
LRI1 | LRS1 | LRS2 | 2 | |||||
LRI3 | LRS1 | LRS2 | 3 | |||||
T1 | S1 | f1 | LRI3 | LRS1 | LRS2 | 4 | ||
LRI2 | LRS1 | LRS2 | 5 | |||||
LRI1 | LRS1 | LRS2 | 6 | |||||
T1 | S2 | f1 | LRI2 | LRS1 | LRS2 | 7 | ||
LRI1 | LRS1 | LRS2 | 8 | |||||
LRI3 | LRS1 | LRS2 | 9 | |||||
T2 | S1 | f1 | LRI3 | LRS1 | LRS2 | 10 | ||
LRI2 | LRS1 | LRS2 | 11 | |||||
LRI1 | LRS1 | LRS2 | 12 | |||||
T2 | S2 | f2 | LRI3 | LRS1 | LRS2 | 13 | ||
LRI2 | LRS1 | LRS2 | 14 | |||||
LRI1 | LRS1 | LRS2 | 15 | |||||
T1 | S2 | f2 | LRI3 | LRS1 | LRS2 | 16 | ||
LRI1 | LRS1 | LRS2 | 17 | |||||
LRI2 | LRS1 | LRS2 | 18 | |||||
T2 | S1 | f2 | LRI1 | LRS1 | LRS2 | 19 | ||
LRI2 | LRS1 | LRS2 | 20 | |||||
LRI3 | LRS1 | LRS2 | 21 | |||||
T2 | S2 | f1 | LRI1 | LRS1 | LRS2 | 22 | ||
LRI2 | LRS1 | LRS2 | 23 | |||||
LRI3 | LRS1 | LRS2 | 24 |
UNS M11917 (AZ91D) | UNS A92024 (AA2024 T351) |
---|---|
Al 8.30–9.70% | Al 90.7–94.7% |
Cu ≤ 0.03% | Cr ≤ 0.1% |
Fe ≤ 0.005% | Cu 3.8–4.9% |
Mg 90% | Fe ≤ 0.5% |
Mn ≥ 0.13% | Mg 1.2–1.8% |
Ni ≤ 0.002% | Mn 0.3–0.9% |
Si ≤ 0.1% | Si ≤ 0.5% |
Zn 0.35–1% | Ti ≤ 0.15% |
- | Zn ≤ 0.25% |
Factors | Levels Values |
---|---|
Feed rate, f, (mm/rev) | 0.10/0.15 |
Spindle speed, S, (rpm) | 925/1470 |
Depth of cut, d, (mm) | 0.25 |
Type of tool, T | HX/CP200 |
Location respect of the specimen, LRS | Beginning of the specimen/End of the specimen |
Location respect of the insert, LRI | Before the insert/On the insert/After the insert |
No. | Test | Position | Ra, (μm) | Observations | |
---|---|---|---|---|---|
LRS1 | LRS2 | ||||
1 | HX_01_TP_P025_V150_A015 | LRI2 | 0.86 | 0.86 | 1 |
LRI1 | 0.88 | 0.93 | 2 | ||
LRI3 | 1.09 | 0.99 | 3 | ||
2 | HX_01_00_P025_V150_A010 | LRI3 | 0.61 | 0.61 | 4 |
LRI2 | 0.49 | 0.48 | 5 | ||
LRI1 | 0.62 | 0.53 | 6 | ||
3 | HX_02_TP_P025_V230_A010 | LRI2 | 0.47 | 0.53 | 7 |
LRI1 | 0.51 | 0.58 | 8 | ||
LRI3 | 0.59 | 0.56 | 9 | ||
4 | CP200_01_TP_P025_V150_A010 | LRI3 | 0.56 | 0.58 | 10 |
LRI2 | 0.45 | 0.43 | 11 | ||
LRI1 | 0.58 | 0.60 | 12 | ||
5 | CP200_01_00_P025_V230_A015 | LRI3 | 1.08 | 0.96 | 13 |
LRI2 | 0.78 | 0.78 | 14 | ||
LRI1 | 0.84 | 0.83 | 15 | ||
6 | HX_02_00_P025_V230_A015 | LRI3 | 1.10 | 1.04 | 16 |
LRI1 | 0.94 | 0.91 | 17 | ||
LRI2 | 0.90 | 0.92 | 18 | ||
7 | CP200_02_TP_P025_V150_A015 | LRI1 | 0.96 | 0.92 | 19 |
LRI2 | 0.84 | 0.93 | 20 | ||
LRI3 | 1.13 | 1.26 | 21 | ||
8 | CP200_02_00_P025_V230_A010 | LRI1 | 0.52 | 0.56 | 22 |
LRI2 | 0.43 | 0.50 | 23 | ||
LRI3 | 0.56 | 0.47 | 24 |
Source | Degrees of Freedom | Sum of Squares | Mean Square | F | Pr > F |
---|---|---|---|---|---|
S | 1 | 0.022 | 0.022 | 5.57 | 0.023 |
f | 1 | 3.920 | 3.920 | 972.28 | <0.001 |
LRI | 2 | 0.340 | 0.170 | 42.20 | <0.001 |
f*LRI | 2 | 0.063 | 0.032 | 7.86 | 0.001 |
T*S | 2 | 0.043 | 0.021 | 5.27 | 0.009 |
Error | 39 | 0.157 | 0.004 | - | - |
Total | 47 | 4.546 | - | - | - |
Test for Normality | Statistic | p-Value | ||
---|---|---|---|---|
Kolmogorov–Smirnov | D | 0.0678 | Pr > D | >0.150 |
Cramer–von Mises | W-Sq | 0.0332 | Pr > W-Sq | >0.250 |
Anderson–Darling | A-Sq | 0.2486 | Pr > A-Sq | >0.250 |
Source | Contribution Percentage (%) |
---|---|
S | 0.49 |
f | 86.23 |
LRI | 7.49 |
f*LRI | 1.39 |
T*S | 0.94 |
Total | 96.54 |
S, (rpm) | LRI | T | f, (mm/rev) | Prediction of Ra, (µm) |
---|---|---|---|---|
1470 | On the insert | CP200 | 0.10 | 0.42 |
925 | On the insert | CP200 | 0.10 | 0.46 |
925 | On the insert | HX | 0.10 | 0.46 |
1470 | On the insert | HX | 0.10 | 0.46 |
1470 | Before the insert | CP200 | 0.10 | 0.53 |
1470 | After the insert | CP200 | 0.10 | 0.53 |
925 | Before the insert | CP200 | 0.10 | 0.57 |
925 | Before the insert | HX | 0.10 | 0.57 |
1470 | Before the insert | HX | 0.10 | 0.57 |
925 | After the insert | CP200 | 0.10 | 0.58 |
925 | After the insert | HX | 0.10 | 0.58 |
1470 | After the insert | HX | 0.10 | 0.58 |
1470 | On the insert | CP200 | 0.15 | 0.80 |
1470 | Before the insert | CP200 | 0.15 | 0.84 |
925 | On the insert | CP200 | 0.15 | 0.87 |
925 | On the insert | HX | 0.15 | 0.87 |
1470 | On the insert | HX | 0.15 | 0.87 |
925 | Before the insert | CP200 | 0.15 | 0.92 |
925 | Before the insert | HX | 0.15 | 0.92 |
1470 | Before the insert | HX | 0.15 | 0.92 |
1470 | After the insert | CP200 | 0.15 | 1.01 |
925 | After the insert | CP200 | 0.15 | 1.10 |
925 | After the insert | HX | 0.15 | 1.10 |
1470 | After the insert | HX | 0.15 | 1.10 |
© 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
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Rubio, E.M.; Villeta, M.; Valencia, J.L.; Sáenz de Pipaón, J.M. Experimental Study for Improving the Repair of Magnesium–Aluminium Hybrid Parts by Turning Processes. Metals 2018, 8, 59. https://doi.org/10.3390/met8010059
Rubio EM, Villeta M, Valencia JL, Sáenz de Pipaón JM. Experimental Study for Improving the Repair of Magnesium–Aluminium Hybrid Parts by Turning Processes. Metals. 2018; 8(1):59. https://doi.org/10.3390/met8010059
Chicago/Turabian StyleRubio, Eva María, María Villeta, José Luis Valencia, and José Manuel Sáenz de Pipaón. 2018. "Experimental Study for Improving the Repair of Magnesium–Aluminium Hybrid Parts by Turning Processes" Metals 8, no. 1: 59. https://doi.org/10.3390/met8010059