Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations

In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness a...

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Autores: Rubio Mateos, Antonio, Rivero Rastrero, María Asunción, Ukar Arrien, Eneko, Lamikiz Mentxaka, Aitzol
Tipo de recurso: artículo
Fecha de publicación:2020
País:España
Institución:Universidad del País Vasco
Repositorio:Addi. Archivo Digital para la Docencia y la Investigación
OAI Identifier:oai:addi.ehu.eus:10810/41918
Acceso en línea:http://hdl.handle.net/10810/41918
Access Level:acceso abierto
Palabra clave:vibrations
part quality
flexible vacuum fixture
AA2024 floor milling
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spelling Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing OperationsRubio Mateos, AntonioRivero Rastrero, María AsunciónUkar Arrien, EnekoLamikiz Mentxaka, Aitzolvibrationspart qualityflexible vacuum fixtureAA2024 floor millingIn finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.This research was funded by Basque Government (Eusko Jaurlaritza) under the ELKARTEK Program, SMAR3NAK project, grant number KK-2019/00051.MDPI2020202020202020info:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10810/41918reponame:Addi. Archivo Digital para la Docencia y la Investigacióninstname:Universidad del País VascoIngléshttps://www.mdpi.com/2075-4701/10/2/289info:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by/3.0/es/© 2020 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/).oai:addi.ehu.eus:10810/419182026-06-18T09:23:17Z
dc.title.none.fl_str_mv Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
title Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
spellingShingle Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
Rubio Mateos, Antonio
vibrations
part quality
flexible vacuum fixture
AA2024 floor milling
title_short Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
title_full Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
title_fullStr Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
title_full_unstemmed Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
title_sort Influence of Elastomer Layers in the Quality of Aluminum Parts on Finishing Operations
dc.creator.none.fl_str_mv Rubio Mateos, Antonio
Rivero Rastrero, María Asunción
Ukar Arrien, Eneko
Lamikiz Mentxaka, Aitzol
author Rubio Mateos, Antonio
author_facet Rubio Mateos, Antonio
Rivero Rastrero, María Asunción
Ukar Arrien, Eneko
Lamikiz Mentxaka, Aitzol
author_role author
author2 Rivero Rastrero, María Asunción
Ukar Arrien, Eneko
Lamikiz Mentxaka, Aitzol
author2_role author
author
author
dc.subject.none.fl_str_mv vibrations
part quality
flexible vacuum fixture
AA2024 floor milling
topic vibrations
part quality
flexible vacuum fixture
AA2024 floor milling
description In finishing processes, the quality of aluminum parts is mostly influenced by static and dynamic phenomena. Different solutions have been studied toward a stable milling process attainment. However, the improvements obtained with the tuning of process parameters are limited by the system stiffness and external dampers devices interfere with the machining process. To deal with this challenge, this work analyzes the suitability of elastomer layers as passive damping elements directly located under the part to be machined. Thus, exploiting the sealing properties of nitrile butadiene rubber (NBR), a suitable flexible vacuum fixture is developed, enabling a proper implementation in the manufacturing process. Two different compounds are characterized under axial compression and under finishing operations. The compression tests present the effect of the feed rate and the strain accumulative effect in the fixture compressive behavior. Despite the higher strain variability of the softer rubber, different milling process parameters, such as the tool feed rate, can lead to a similar compressive behavior of the fixture regardless the elastomer hardness. On the other hand, the characterization of these flexible fixtures is completed over AA2024 floor milling of rigid parts and compared with the use of a rigid part clamping. These results show that, as the cutting speed and the feed rate increases, due to the strain evolution of the rubber, the part quality obtained tend to equalize between the flexible and the rigid clamping of the workpiece. Due to the versatility of the NBR for clamping different part geometries without new fixture redesigns, this leads to a competitive advantage of these flexible solutions against the classic rigid vacuum fixtures. Finally, a model to predict the grooving forces with a bull-nose end mill regardless of the stiffness of the part support is proposed and validated for the working range.
publishDate 2020
dc.date.none.fl_str_mv 2020
2020
2020
2020
dc.type.none.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv http://hdl.handle.net/10810/41918
url http://hdl.handle.net/10810/41918
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv https://www.mdpi.com/2075-4701/10/2/289
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by/3.0/es/
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by/3.0/es/
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv MDPI
publisher.none.fl_str_mv MDPI
dc.source.none.fl_str_mv reponame:Addi. Archivo Digital para la Docencia y la Investigación
instname:Universidad del País Vasco
instname_str Universidad del País Vasco
reponame_str Addi. Archivo Digital para la Docencia y la Investigación
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