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The Aplication of Vibro – Abrasive Machining for Smoothing of Castings

D. Bańkowski S. Spadło
Archives of Foundry Engineering | 2017 | vol. 17 | No 1 | DOI: 10.1515/afe-2017-0031
Keywords Castings Vibro-abrasive machining Finishing Burrs removal Surface quality
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Abstract

The paper presents the production problems related to casting using precision casting methods. The essential adverse effect of the casting

process is the presence of burrs understood as oversize material necessary to remove the next finishing operations. In addition, the surfaces

of the cast often characterized by a porous structure. One of the methods to improve the smoothness of the area proposed by the authors is

the use of vibro-abrasive finishing. This type of treatment is widely used in the treatment of finishing small objects as well as complex

shapes. Objects in the form of casting in the first step was treated with aggressive deburring polyester matrix abrasive media. The second

stage was polishing, with using smoothing porcelain media. The study evaluated the effect of vibro-abrasive machining typical cast on the

basic parameters of the geometric structure of the surface. Observations using optical microscope Nicon Eclipse MA 200 compared

changes in surface microstructure and the effect of deburring. Clearly we can say that vibro-abrasive machining an effective way

of reducing the size of burrs, smoothing and lightening the surface of objects made by casting.

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Authors and Affiliations

D. Bańkowski
S. Spadło

Effects of EDM on the Chemical Composition and Microstructure of the Surface Layer of Alnico Alloys

D. Bańkowski P. Młynarczyk B. Szwed
Archives of Foundry Engineering | 2023 | vol. 23 | No 2 | 106-111 | DOI: 10.24425/afe.2023.144301
Keywords Electrical discharge machining (EDM) Alnico Chemical composition Roughness Surface quality
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Abstract

This article deals with the effects of electrical discharge machining (EDM) on the chemical composition and microstructure of cast Alnico alloys, i.e., iron-based alloys composed of aluminum, nickel and cobalt. The experiments focused on determining the chemical composition of the surface layer before and after the EDM process. The microstructure of the material altered by the EDM was also examined. The study included measurement of the thickness of the white layer characteristic of EDM. It is evident that low values of the surface roughness parameters can be obtained by correctly selecting the EDM process parameters. The average surface roughness reported in the experiments was 1 μm. The surface roughness measurements were conducted with a Talysurf CCI lite non-contact profiler. The metrological results also indicate that lower surface roughness can be obtained at small discharge energies.
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Authors and Affiliations

D. Bańkowski
1
ORCID: ORCID
P. Młynarczyk
1
ORCID: ORCID
B. Szwed
1
ORCID: ORCID
  1. Kielce University of Technology, Poland

Experimental Research on the Influence of Roughness of the Machined Surface of a Part on Galvanization

Sandor Ravai-Nagy Alina Bianca Pop Marcin Nabiałek Costin Alexandru Mihail Aurel Țîțu
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 4 | 1591-1595 | DOI: 10.24425/amm.2023.146227
Keywords Surface quality turning pickling hot dip galvanizing optimization
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Abstract

The purpose of this scientific paper is to follow the influence of thermal galvanizing, as a technological process on the quality of the galvanized surface. The galvanizing technology used and studied involves at the end of the process, the removal of excess zinc from the surface by centrifugation. The zinc layer will be lower than that of simple immersion galvanizing. The measurements were performed following the roughness of the machined surface on a five-Section specimen – each Section being processed with a different cutting regime. The results were analyzed after each operation. The first measurements were made after the turning operation, followed by measurements made after pickling and fluxing and then after thermal galvanizing. Based on the results obtained, the aim was to set up a range of best roughness at which the galvanized part should have a commercial appearance and be made with a cost-effective cutting regime in terms of costs.
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Authors and Affiliations

Sandor Ravai-Nagy
1
ORCID: ORCID
Alina Bianca Pop
1
ORCID: ORCID
Marcin Nabiałek
2
ORCID: ORCID
Costin Alexandru
3
ORCID: ORCID
Mihail Aurel Țîțu
4
ORCID: ORCID
  1. Technical University of Cluj-Napoca, Northern Un iversity Cent re of Baia Mare, Faculty of Engineering – Department of Engineering and Technology Management , 62A, Vict or Babes Street, 430083, Baia Mare, Maramures, Romania
  2. Częstochowa University of Technology, Department of Physics , Armii Krajowej 19 Av., 42-200 Częstochowa
  3. Electro Sistem, 4B, 8 Martie Street, 430406, Baia Mare, Maramures, Romania
  4. ”Lucian Blaga” University of Sibiu, Faculty of Engineering, Industrial Engineering and Management Department , 10 Victoriei Street, 550024, Sibiu, Romania

Effect of Flap Peening Speed on the Surface Quality and Micro Hardness of Aircraft Aluminum Alloys

Nabeel Abu Shaban Nabeel Alshabatat Safwan Al-Qawabah
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 3 | 855-862 | DOI: 10.24425/amm.2022.139675
Keywords Surface roughness Surface quality Material processing Flap speed Surface hardness
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Abstract

Flap peening (FP) is a cold working technique used to apply a compressive force using small shots, this will lead to enhance the surface properties that it can sustain for long life during working conditions. In this study, several aircraft aluminum alloys materials namely; 2219 T6, 2024 T6, 7075T6, and 6061 T6 were flap peened under different rotational speeds. The effect of rotational speed on the average surface roughness (Ra) and average surface micro hardness have been investigated. As seen by the Scanning Electron Microscope SEM phots that the hardness of peened layer is increased. It was found that as the flap peening speeds increase the percent change in surface roughness (Ra) increases, and the percent change in surface micro hardness decreases. The maximum increase in Ra occurs in 2219 T80 and the minimum in 6061 T6 alloys, and for hardness, it is reported that the maximum occurs in 6061 T6 and the minimum in 2019 T80 alloy.
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Authors and Affiliations

Nabeel Abu Shaban
1
ORCID: ORCID
Nabeel Alshabatat
2
Safwan Al-Qawabah
1
ORCID: ORCID
  1. Al-Zaytoonah University of Jordan, Mechanical Engineering Department, Amman, Jordan
  2. Tafila Technical University, Mechanical Engineering Department, Tafila 66110, Jordan

The Use of Floster S Technology in Modified Ablation Casting of Aluminum Alloys

J. Kamińska M. Angrecki S. Puzio M. Hosadyna-Kondracka K. Major-Gabryś
Archives of Foundry Engineering | 2019 | vol. 19 | No 4 | 81-86 | DOI: 10.24425/afe.2019.129634
Keywords Moulding sands Ablation casting Water glass Floster S Mechanical properties of casting Surface quality
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Abstract

Ablation casting is a technological process in which the increased cooling rate causes microstructure refinement, resulting in improved mechanical properties of the final product. This technology is particularly suitable for the manufacture of castings with intricate shapes and thin walls. Currently, the ablation casting process is not used in the Polish industry. This article presents the results of strength tests carried out on moulding sands based on hydrated sodium silicate hardened in the Floster S technology, intended for ablation casting of the AlSi7Mg (AK7) aluminium alloy. When testing the bending and tensile strengths of sands, parameters such as binder and hardener content were taken into account. The sand mixtures were tested after 24h hardening at room temperature. The next stage of the study describes the course of the ablation casting process, starting with the manufacture of foundry mould from the selected moulding mixture and ending in tests carried out on the ready casting to check the surface quality, structure and mechanical properties. The results were compared with the parallel results obtained on a casting gravity poured into the sand mould and solidifying in a traditional way at ambient temperature.

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Authors and Affiliations

J. Kamińska
ORCID: ORCID
M. Angrecki
ORCID: ORCID
S. Puzio
ORCID: ORCID
M. Hosadyna-Kondracka
ORCID: ORCID
K. Major-Gabryś
ORCID: ORCID

The Effect of Reclaim Primary Quality on Moulding Sand Parameters and Quality of Ductile Iron Casting Surface Layer

J. Kamińska M. Angrecki S. Puzio M. Stachowicz
Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 83-88 | DOI: 10.24425/afe.2022.140229
Keywords Foundry industry Furfuryl resin Reclaim Self-hardening moulding sand Surface quality
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Abstract

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.
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Bibliography

[1] Lewandowski, J.L. (1997). Materials for foundry moulds. Kraków: WN Akapit. ISBN: 83-7108-21-2 (in Polish).
[2] Kamińska, J., Puzio, S., Angrecki, M., Stachowicz, M. & Łoś, A. (2019). Preliminary tests of innovative eco-friendly furfuryl resins and foundry sand mixtures based on these resins. Journal of Ecological Engineering. 20(9), 285-292, DOI: 10.12911/22998993/112510.
[3] Acharya, S.G., Vadher, J.A. & Kanjariya, P.V. (2016). Identification and quantification of gases releasing from furan no bake binder. Archives of Foundry Engineering. 16(3), 5-10. DOI: 10.1515/afe-2016-0039.
[4] Chate, G.R., Patel, GC M., Deshpande, A.S. & Parappagoudar, M.B. (2018). Modeling and optimization of furan moulding sand system using design of experiments and particle swarm optimization. Journal of Process Mechanical Engineering. 232(5), 1-20. DOI: 10.1177/0954408917728636.
[5] Sappinen, T., Orkas, J. & Konqvist, T. (2018). Thermal Reclamation of Foundry Sands Using Repurposed Sand Dryer Equipment. Archives of Foundry Engineering. 18(4), 99-102. DOI: 10.24425/afe.2018.125176.
[6] Kamińska, J., Puzio, S., Angrecki, M. & Łoś, A. (2020). Effect of reclaim addition on the mechanical and technological properties of moulding sands based on pro-ecological furfuryl resin. Archives of Metallurgy and Materials. 65(4), 1425-1429. DOI: 10.24425/amm.2020.133709.
[7] Yan-lei, L., Guo-hua, W., Wen-cai, L., An-tao, C., Liang, Z. & Ying-xin Wang, W. (2017). Effect of reclaimed sand additions on mechanical properties and fracture behavior of furan no-bake resin sand. China Foundry. 14(2), 128-137. DOI: 10.1007/s41230-017-6024-3.
[8] Holtzer, M., Dańko, R., Kmita, A., Drożyński, D., Kubecki, M., Skrzyński, M. & Roczniak, A. (2020). Environmental impact of the reclaimed sand addition to moulding sand with furan and phenol-formaldehyde resin—A comparison, Materials. 13(19), 4395; DOI: https://doi.org/10.3390/ma13194395.
[9] Holtzer, M., Dańko, R. & Kmita, A. (2016). Influence of a reclaimed sand addition to moulding sand with furan resin on its impact on the environment. Water Air and Soil Pollution. 227(16), 1-12. DOI: 10.1007/s11270-015-2707-9.
[10] Hosadyna, M. (2012). The effect of sulphur contained in self-hardening moulding sands on the structure of surface layer in ductile iron castings. Doctoral dissertation, Kraków. (in Polish).
[11] Holtzer, M., Zych, J. & Retel, K. (1996). The effect of mould-liquid cast iron interaction on the surface quality of castings. Przegląd Odlewnictwa. 6(1996), 129-134. (in Polish).
[12] Riposan, I., Chisamera, M., Stan, S., Skaland, T. (2008). Surface graphite degeneration in ductile iron castings for resin molds. Tsinghua Science and Technology. 13(2), 157-163.
[13] Linke, T., Sluis, J.R. (1993). The influence of coatings on the graphite structure in the rim-zone of ductile iron castings. 60th World Foundry Congress, The Netherlands
[14] Hosadyna, M., Dobosz, St.M. & Jelinek, P. (2009). The diffusion of sulphur from moulding sand to cast and methods of its elimination. Archives of Foundry Engineering. 9(4), 73-76.
[15] Sheladiya, M.V., Acharya, S.G., Mehta, K., Acharya, G.D. (2019). Evaluate sulphur diffusion at mould-metal interface in no-bake mould system. Archives of Foundry Engineering. 19(1), 63-70. DOI: 10.24425/afe.2018.125193.
[16] Anca, D., Stan, I., Chisamera, M., Riposan, I. & Stan, S. (2021). Experimental study regarding the possibility of blocking the diffusion of sulfur at casting-mold interface in ductile iron castings. Coatings. 11(673), 1-10. DOI: https://doi.org/10.3390/coatings11060673.
[17] Dańko, J., Dańko, R. & Łucarz, M. (2007). Processes and devices for the matrix regeneration of spent molding sands. Kraków: WN Akapit. ISBN: 978-83-89541-88-8 (in Polish).
[18] Holtzer, M., Bobrowski, A., Drożyński, D., Isendorf, B., Mazur, (2012). Influence of the reclaim on the properties of moulding sands with furfuryl resin applied for moulds for manganese steel castings. Archives of Foundry Engineering. 12(1), 57-62.
[19] Dańko, R., Górny, M., Holtzer, M., Żymankowska-Kumon, S. (2014). Effect of the quality of furan moulding sand on the skin layer of ductile iron castings. ISIJ International. 54(6), 1288-1293. DOI: https://doi.org/10.2355/isijinternational.54.1288.
[20] Pałyga, Ł., Stachowicz, M., Granat, K. (2015). Evaluation of 2D and 3D surface roughness of die castings from alloy AlSi9Cu3. Archives of Foundry Engineering. 15(1), 75-80.

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Authors and Affiliations

J. Kamińska
1
ORCID: ORCID
M. Angrecki
1
ORCID: ORCID
S. Puzio
1
ORCID: ORCID
M. Stachowicz
2
ORCID: ORCID
  1. Łukasiewicz Research Network – Krakow Institute of Technology, Poland
  2. Wroclaw University of Technology, Faculty of Mechanical Engineering, Poland

Experimental modeling of the milling process of aluminum alloys used in the aerospace industry

Aurel Mihail Titu Alina Bianca Pop Marcin Nabiałek Camelia Cristina Dragomir Andrei Victor Sandu
Bulletin of the Polish Academy of Sciences Technical Sciences | 2021 | 69 | 5 | e138565 | DOI: 10.24425/bpasts.2021.138565
Keywords mathematical modeling experimental research process parameters machined surface quality quality assurance
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Abstract

This research presents an experimental study carried out for the modeling and optimization of some technological parameters for the machining of metallic materials. Certain controllable factors were analyzed such as cutting speed, depth of cut, and feed per tooth. A dedicated research methodology was used to obtain a model which subsequently led to a process optimization by performing a required number of experiments utilizing the Minitab software application. The methodology was followed, and the optimal value of the surface roughness was obtained by the milling process for an aluminum alloy type 7136-T76511. A SECO cutting tool was used, which is standard in aluminum machining by milling. Experiments led to defining a cutting regime that was optimal and which shows that the cutting speed has a significant influence on the quality of the machined surface and the depth of cut and feed per tooth has a relatively small impact on the chosen ranges of process parameters.
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Bibliography

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  5.  A.M. Ț î țu and A.B. Pop, “A Comparative Analysis of the Machined Surfaces Quality of an Aluminum Alloy According to the Cutting Speed and Cutting Depth Variations”, Lecture Notes in Network and Systems: New Technologies, Development and Application , vol II, no. 76, pp. 212‒218, 2019.
  6.  A.B. Pop and A.M. Ț î țu, “A Comparative Analysis of the Machined Surfaces Quality of an Aluminum Alloy According to the Cutting Speed and Feed per Tooth Variations”, Lecture Notes in Network and Systems: New Technologies, Development and Application, vol II, no. 76, 238‒244, 2019.
  7.  A.M. Ț îțu, A.V. Sandu, A.B. Pop, Ș. Țîțu, and T.C. Ciungu, “The Taguchi Method application to improve the quality of a sustainable process”, IOP Conf. Ser.: Mater. Sci. Eng., vol. 374, p. 012054, 2018.
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  13.  P. Sahoo, “Optimization of turning parameters for surface roughness using RSM and GA”, Adv. Prod. Eng. Manag., vol. 6 no. 3, pp. 197– 208, 2011.
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Authors and Affiliations

Aurel Mihail Titu
1 2
ORCID: ORCID
Alina Bianca Pop
3
ORCID: ORCID
Marcin Nabiałek
4
ORCID: ORCID
Camelia Cristina Dragomir
2 5
Andrei Victor Sandu
6 7
ORCID: ORCID
  1. Lucian Blaga University of Sibiu, 10 Victoriei Street, 550024, Sibiu, Romania
  2. The Academy of Romanian Scientists, 54 Splaiul Independenței, Sector 5, 050085, Bucharest, Romania
  3. Technical University of Cluj-Napoca, 62A Victor Babeș Street, Baia Mare, Romania
  4. Department of Physics, Częstochowa University of Technology, Al. Armii Krajowej 19, 42-200 Częstochowa, Poland
  5. Transilvania University of Brasov, 500036 Brasov, Romania
  6. Gheorghe Asachi Technical University, Blvd. D. Mangeron 71, 700050 lasi, Romania
  7. Romanian Inventors Forum, Str. Sf. P. Movila 3, 700089 Iasi, Romania

Machinability Studies on the Turning of Magnesium Metal Matrix Composites

K. Gobivel K.S. Vijay Sekar
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 3 | 939-948 | DOI: 10.24425/amm.2022.139686
Keywords Mg-SiCp composite cutting forces Surface quality chip microstructure tool morphology
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Abstract

Magnesium-based MMCs are widely used in structural-based applications due to their lightweight, high hardness, corrosion and wear resistance. Also, machining is an important manufacturing process that is necessary to ensure dimensional accuracy and produce intricate shapes. In this context, the machining of Magnesium based metal matrix composites is undertaken to study the impact of the cutting parameters on the machinability behaviour. In this work, turning of pure Mg/SiCp on a Lathe is done and an in-depth assessment on the machining forces, machined surface quality, chip microstructure, and tool morphology has been carried out using TiAlN coated tooling insert. The analysis revealed that the thrust force decreased due to the thermal softening of the matrix meanwhile the feed force also followed the similar trend at higher cutting speeds because of the minimized built-up edge and cutting depth whereas principal cutting force was inconsistent at higher cutting speeds. The surface finish was better at high cutting speed – low feed combination. The chip microstructure revealed that gross fracture propagation at the free surface and variations in the shear bands have occurred at different cutting speeds. Tool studies using SEM analysis revealed wear modes like chipping and built-up edge at low cutting speeds, but with a reduced impact at intermediate cutting conditions, whereas abrasion wear was observed predominantly in the tool nose at higher cutting speeds.
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Authors and Affiliations

K. Gobivel
1
ORCID: ORCID
K.S. Vijay Sekar
2
ORCID: ORCID
  1. KCG College of Technology, Karapakkam, Chennai, India
  2. Sri Sivasubramaniya Nadar College of Engineering, Kalavakkam, India

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