Helical milling has been positioned as an alternative to conventional drilling, where the advantages it offers make it very attractive for use on difficult-to-machine alloys such as the titanium alloy UNS R56400. However, the correlation between the indicator of hole quality and the kinematic parameters has rarely been studied. The kinematics are what bring most advantages and that is why it is necessary to know their influence. In this aspect, there are different focuses of problems associated with the complexity of the process kinematics, which makes it necessary to undertake a deeper analysis of the process and to carry out a preliminary study. To address this problem, a DOE (Design of Experiments) is proposed to identify the sensitivity and the main trends of the properties that define the quality holes with respect to the kinematic parameters. At the same time, a nomenclature is proposed to unify and avoid misinterpretations. This study has allowed us to obtain conclusive results that offer very relevant information for future research

Transfer of cutting material to cutting tool during machining process of aluminum alloys, is strongly related with the secondary/indirect adhesion wear mechanisms in form of Built-Up Layer (BUL) and Built-Up Edge (BUE). BUL and BUE formation and their evolution modify the physicochemical and geometry properties of the tool. Much uncertainty still exists about the relationship between surface finish and BUL-BUE intensity, mainly due to the difficulty found in characterizing and quantifying the material adhered onto the tool. In this paper, tool wear effects in dry turning of aerospace alloy UNS A92024-T3 (Al-Cu) have been analyzed from two standpoints. First, a metrological methodology based on Focus-Variation Microscopy (FVM) is proposed to evaluate the intensity of tool wear in form of BUE. Second, a set of roughness parameters is proposed to evaluate the influence of turning parameters in terms of root mean square deviation, skewness and kurtosis of the roughness assessed profile

High compression forces developed during machining processes -and the subsequent energy transferred - carry on changes in the workpiece surface. These changes are usually evaluated only from dimensional or geometrical viewpoints and less frequently form the point of view of the physicochemical surface properties. Notwithstanding, some works relating geometrical and physicochemical properties of machined surfaces can be found in the literature. It is well known that geometrical features of machined surfaces are strongly related to the cutting parameters. Therefore, it can be thought that physicochemical properties of machined surfaces depend strongly on machining parameters. This work reports on the results of a study of the influence of the turning parameters on the Ultimate Tensile Strength (UTS) of turned bars of UNS A92024 Aluminium-Copper alloy.

At present, the use of titanium alloys is increasing in a wide range of applications in different industrial sectors, especially in the aerospace industry. Machining is a very important process in this sector. However, aeronautical titanium alloys are classified as materials that are difficult to machine. A very current technique in the research field of machining by material removal is the use of simulations using the Finite Element Method (FEM). These simulations can notably reduce the number of experimental tests and allow obtaining a first approximation of the process without the need for long-lasting and expensive experiments. This paper presents a methodology for the geometrical definition of common contour-mill tools used in the aerospace industry. Through the section of the active cutting area of the tool and using optical measurements, a 3D model of the tool can be produced. Afterwards, the 3D solid model is imported to FEM software, where the study of it is possible for improving the performance of the machining process.

The influence of the forming process in the response into service of the manufactured workpieces, in the first instance, through the surface integrity can be evaluated. The concept of surface integrity includes the assessment of geometrical aspects like shape and dimensions, and physicochemical properties like hardness and corrosion resistance. This work reports on the results of a study of the influence of the turning parameters on the Ultimate Tensile Strength (UTS) of turned bars of UNS A92024 Aluminium-Copper alloy.

In this work, the results of a preliminary study on the dry turning of the UNS A92050-T84 alloy (Al–Cu–Li, third generation of Al–Li alloys) are shown. This study has been focused on the analysis of the final surface quality of the machined workpieces, in terms of average roughness (R_a). Dry turning tests have been performed, using symmetric WC-Co cutting-tools, with different feeds and cutting speeds. Two different geometrical models, linear and quadratic, have been proposed, together with a non-geometrical potential model, obtained by adjusting the measurements to empirical data. Although the linear geometrical model is far from the acquired data, this model is formally similar to the parametric model, in which the feed exponent is close to one. This model allows predicting roughness theoretically for similar range of cutting conditions.