Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures

The aeronautic industry is facing many challenges regarding the lifetime, weight and accuracy that aircraft skins must comply to meet stringent structural and aerodynamic requirements. Currently, mechanical milling of aircraft skin parts of 2024-T3 aluminum alloy is displacing the highly pollutant c...

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Autores: Casuso Lomas, Mikel, Rubio Mateos, Antonio, Veiga Suárez, Fernando, Lamikiz Mentxaka, Aitzol
Formato: artículo
Fecha de publicación:2022
País:España
Recursos:Universidad del País Vasco
Repositorio:Addi. Archivo Digital para la Docencia y la Investigación
OAI Identifier:oai:addi.ehu.eus:10810/59624
Acesso em linha:http://hdl.handle.net/10810/59624
Access Level:acceso abierto
Palavra-chave:AA 2024 T3 aluminum alloy
frce modeling
thin floor
thin parts milling
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spelling Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixturesCasuso Lomas, MikelRubio Mateos, AntonioVeiga Suárez, FernandoLamikiz Mentxaka, AitzolAA 2024 T3 aluminum alloyfrce modelingthin floorthin parts millingThe aeronautic industry is facing many challenges regarding the lifetime, weight and accuracy that aircraft skins must comply to meet stringent structural and aerodynamic requirements. Currently, mechanical milling of aircraft skin parts of 2024-T3 aluminum alloy is displacing the highly pollutant chemical milling. Consequently, flexible and reconfigurable vacuum holding fixtures are being increasingly employed, because they are adaptable to several part geometries, but, since their rigidity is extremely reduced, the low stiffness of parts limits severely their deployment. Aiming to harness the full potential of these holding systems for aluminum alloy skin parts, a complete analysis of final thickness achieved and cutting force is developed. Thin floor parts of different geometries are pocket milled, simply screwed at their corners, emulating a skin part supported by four vacuum cups. Process forces are continuously monitored, and final thickness is measured. It has been proven that the reduction of mass and stiffness during milling causes a corresponding reduction of the natural frequencies of the parts. Also, as long as natural frequencies are not excited, final thickness error is almost constant and not affected by the tool position, but only by the initial geometry and fixtures distribution of the part. Additionally, a new cutting force model for skin parts is empirically calculated. Unlike models designed for fully supported parts, this model is designed for skins held in flexible fixtures. It has a relative error of 5.6% and it allows to optimize the trajectory, geometry and support distribution, thus boosting the use of flexible fixtures.Financial support from the Basque Government under the ELKARTEK Program (EKOHEGAZ project, grant number KK-2021/00092) is gratefully acknowledged by the authors.Elsevier202320232022info:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10810/59624reponame:Addi. Archivo Digital para la Docencia y la Investigacióninstname:Universidad del País VascoIngléshttps://www.sciencedirect.com/science/article/pii/S223878542201609X?via%3Dihubinfo:eu-repo/semantics/openAccesshttp://creativecommons.org/licenses/by-nc-nd/3.0/es/© 2022 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http:// creativecommons.org/licenses/by-nc-nd/4.0/).Atribución-NoComercial-SinDerivadas 3.0 Españaoai:addi.ehu.eus:10810/596242026-06-18T09:23:17Z
dc.title.none.fl_str_mv Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
title Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
spellingShingle Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
Casuso Lomas, Mikel
AA 2024 T3 aluminum alloy
frce modeling
thin floor
thin parts milling
title_short Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
title_full Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
title_fullStr Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
title_full_unstemmed Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
title_sort Modeling of cutting force and final thickness for low stiffness 2024-T3 aluminum alloy part milling considering its geometry and fixtures
dc.creator.none.fl_str_mv Casuso Lomas, Mikel
Rubio Mateos, Antonio
Veiga Suárez, Fernando
Lamikiz Mentxaka, Aitzol
author Casuso Lomas, Mikel
author_facet Casuso Lomas, Mikel
Rubio Mateos, Antonio
Veiga Suárez, Fernando
Lamikiz Mentxaka, Aitzol
author_role author
author2 Rubio Mateos, Antonio
Veiga Suárez, Fernando
Lamikiz Mentxaka, Aitzol
author2_role author
author
author
dc.subject.none.fl_str_mv AA 2024 T3 aluminum alloy
frce modeling
thin floor
thin parts milling
topic AA 2024 T3 aluminum alloy
frce modeling
thin floor
thin parts milling
description The aeronautic industry is facing many challenges regarding the lifetime, weight and accuracy that aircraft skins must comply to meet stringent structural and aerodynamic requirements. Currently, mechanical milling of aircraft skin parts of 2024-T3 aluminum alloy is displacing the highly pollutant chemical milling. Consequently, flexible and reconfigurable vacuum holding fixtures are being increasingly employed, because they are adaptable to several part geometries, but, since their rigidity is extremely reduced, the low stiffness of parts limits severely their deployment. Aiming to harness the full potential of these holding systems for aluminum alloy skin parts, a complete analysis of final thickness achieved and cutting force is developed. Thin floor parts of different geometries are pocket milled, simply screwed at their corners, emulating a skin part supported by four vacuum cups. Process forces are continuously monitored, and final thickness is measured. It has been proven that the reduction of mass and stiffness during milling causes a corresponding reduction of the natural frequencies of the parts. Also, as long as natural frequencies are not excited, final thickness error is almost constant and not affected by the tool position, but only by the initial geometry and fixtures distribution of the part. Additionally, a new cutting force model for skin parts is empirically calculated. Unlike models designed for fully supported parts, this model is designed for skins held in flexible fixtures. It has a relative error of 5.6% and it allows to optimize the trajectory, geometry and support distribution, thus boosting the use of flexible fixtures.
publishDate 2022
dc.date.none.fl_str_mv 2022
2023
2023
dc.type.none.fl_str_mv info:eu-repo/semantics/article
format article
dc.identifier.none.fl_str_mv http://hdl.handle.net/10810/59624
url http://hdl.handle.net/10810/59624
dc.language.none.fl_str_mv Inglés
language_invalid_str_mv Inglés
dc.relation.none.fl_str_mv https://www.sciencedirect.com/science/article/pii/S223878542201609X?via%3Dihub
dc.rights.none.fl_str_mv info:eu-repo/semantics/openAccess
http://creativecommons.org/licenses/by-nc-nd/3.0/es/
Atribución-NoComercial-SinDerivadas 3.0 España
eu_rights_str_mv openAccess
rights_invalid_str_mv http://creativecommons.org/licenses/by-nc-nd/3.0/es/
Atribución-NoComercial-SinDerivadas 3.0 España
dc.format.none.fl_str_mv application/pdf
dc.publisher.none.fl_str_mv Elsevier
publisher.none.fl_str_mv Elsevier
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
collection Addi. Archivo Digital para la Docencia y la Investigación
repository.name.fl_str_mv
repository.mail.fl_str_mv
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score 15,300724

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