René Leroy

Influence of Minimum Quantity Lubrication on Friction Coefficient and Work-Material Adhesion During Machining of Cast Aluminum With Various Cutting Tool Substrates Made of Polycrystalline Diamond, High Speed Steel, and Carbides

Due to the increasing emphasis on environmental constraints, industry works on how to limit the massive use of lubricants by using the micro-pulverization of oil in machining processes and, especially, in the machining of aluminum alloys for the automotive industry. The success of a machining operation is dependent on a friction coefficient and weak adhesion with the tool-work material interface. This paper aims at identifying the influence of cutting tool substrates (high speed steel (HSS), carbide, polycrystalline diamond (PCD)) and of minimum quantity lubrication (MQL) on the friction coefficient and on adhesion in tribological conditions corresponding to the ones observed in the cutting of aluminum alloys (sliding velocity: 20-1500 m/min). An open ball-on-cylinder tribometer, especially designed to simulate these tribological conditions through Hertz contact, has been used. It has been shown that HSS and carbide substrates lead to large friction coefficients (0.8–1) and substantial adhesion in dry conditions, whereas PCD substrates would lead to lower average friction coefficient values (0.4–0.5) and very limited adhesion, which proves the necessity of using PCD tools in the dry machining of aluminum. It has also been shown that the application of MQL leads to a large decrease of the friction coefficient (0.1–0.2) and eliminates almost all traces of adhesions on pins for any substrates, which shows that MQL is an interesting compromise between dry machining and flood cooling.

Dynamic Mechanical Properties and Thermal Effect of an Epoxy Resin Composite, Encapsulation’s Element of a New Electronic Component

Epoxy resin is used in many industrial applications principally in the microelectronic field to protect integrated circuits. However, these components are subject to various environments such as moisture and thermal fluctuations during packaging. Consequently, mechanical, physical and chemical properties of the resin can be affected. For an epoxy resin composite designed for a future application, an evaluation of the relevant properties was carried out using a dynamic mechanical analyzer and a thermogravimetric analysis (TGA) instrument. The surface morphology was investigated using scanning electron microscopy to examine the impact of post-cured treatment through evolution of the rigidity and of the glass transition temperature. Subsequently, a temperature classification was proposed to define the temperature limit for safe use of the material. Finally, temperature degradation was observed and confirmed by TGA tests. Results from all of these analyses bring understanding to the phenomenon of thermal degradation and its influence on the stability of the epoxy resin composite.

Machining carbon fibre reinforced plastics: lead angle effect

Surface milling of a multiaxial [(45/90/135/0)16]s carbon fibres reinforced plastic was investigated experimentally. A comparison between 19° and 60° lead angle tool are related in this study. The aim was to compare the cutting behaviour of a 19° and a 60° lead angle tool. Several points of comparison have been chosen such like cutting force, material temperature, milled surface roughness, delamination and tool wear. A wide range of cutting conditions was tested with a depth of cut equals to four plies in order to minimise the influence of plies orientation. This previous factor has been widely describe in the literature. Cutting results with 19° lead angle have shown reducing in cutting force, less wear and less delamination in comparison with 60° this results are partly explained by the insert geometry.

Tool design effect on microlubrication spray efficiency in milling using inner channels

This study consisted in investigating parameters that significantly influence the spray efficiency of minimum quantity lubrication in a milling tool with inner channels. An initial experimental approach was used to estimate the oil mist consumption and outlet particle velocities with different inlet pressures, for different shapes of inner channels, without rotation (static part). An experimental versus simulation comparison was undertaken between outlet velocities as a function of inlet pressure. The Reynolds-averaged Navier–Stokes model with the Lagrangian multiphase models was validated by comparing experimental and numerical outlet velocities for different inlet pressures. A numerical rotating tool with inner channels was used with the validated model in the second numerical simulation to analyze the influences of inlet conditions (inlet pressure) based on the tool shape and the rotation velocity, in a dynamic approach. The main objective of the oil mist is to reach the cutting edge (qualifying the minimum quantity lubrication spray efficiency) depending on the inlet conditions (inlet pressures) and the machining configurations (rotation velocities) by analyzing the streamlines of the oil mist particles. The study pointed out the tool design effect combined with its rotation velocity on the oil mist capability to reach the cutting edge. This study offered a trend of parameter sets to provide correct inlet parameters based on machining configurations. At high rotation speed, the inlet pressures needed to be high enough to counter the aerodynamic effects occurred by the tool design.

Dynamic characterization of the cutting conditions in dry turning

Machining instability in the form of violent vibrations or chatter is a physical process characterized by extreme cutting force at the cutting point. The process has very negative impact on machine integrity, tool life, surface quality and dimensional accuracy. Thus it could significantly compromise productivity and manufacturing quality. In the present paper, the importance of characterization and identification of dynamic instability in dry turning operation are shown. The stability behaviour of machine vibration or chatter has been examined and the various relevant parameters are studied and discuted. For chatter detection and identification of the transition between stable and unstable states, different methods are used. Results obtained proof the accuracy of these methods.

Effects of Cutting Angles in Ti-6al-4v Milling Process on Surface Integrity: Influence of Roughness and Residual Stresses on Fatigue Limit

□ The influence of the milling process on the fatigue behavior of a titanium alloy was investigated. The effect of cutting conditions such as the cutting angles (axial and radial rake angle) on the surface integrity (roughness and the residual stresses) was observed. The results indicated that the cutting angles have a limited influence on roughness parameters, whereas the effects on residual stresses were greater. A negative axial rake angle induced compressive residual stresses regardless of the radial rake angle. In contrast, a positive axial rake angle combined with negative radial rake angle induced tensile residual stresses. To evaluate the fatigue limit, the four point fatigue tests were carried out. Result showed the fatigue limit is sensitive to the surface integrity. The fatigue limit was also evaluated by analytical method (Arola model). A good correlation was found between the analytical results and the experimental results when cutting angles induced compressive residual stress. However the Arola model was less accurate for tensile residual stress surface condition. To improve the prediction precision, the residual stress was considered as a sensitivity parameter and added to Arola model.

Variable Amplitude Fatigue

Fatigue crack growth behavior of selected aluminum alloys under variable amplitude loading is discussed in this study, based principally on experimental observations. The tests include single overloads tests in different environments, block load tests and tests using an aircraft wing loading spectrum. It is shown that conditions favoring a planar slip behavior lead to very high delays as opposed to conditions leading to multiple slip behavior. The Aluminium Liithium alloy studied here, has the best fatigue crack growth resistance in almost all test conditions studied here as compared to other conventional alloys. Under the spectrum loading studied here, the same alloy exhibits a change in micromechanism leading to a four fould acceleration of growth rates. Acceptable life predictions can be made, by taking into account this crack acceleration effect.

Optimal milling conditions of aeronautical composite material under temperature, forces and vibration parameters

Optimal conditions for milling carbon/epoxy composite material were established by response surface methodology. The combination of cutting parameters such as cutting speed (Vc) and chip thickness (h) was set at various design points of a central composite design. Significant regression models describing the changes of vibration level, delamination of composite, cutting force, workpiece temperature were developed with the coefficient of determination greater than 0.90. Results suggested that beyond a threshold of vibration, the occurrence of delamination is regular. Vibration criterion was defined from the observations of the workpiece according to the delamination defect. The optimum milling conditions were graphically represented using design contour plots. The best combination of process variables was found, according to the cutting conditions. This new technique should help the operator to select the optimum cutting conditions such as cutting speed and feed rate (chip thickness) in order to avoid damage to the carbon/epoxy composite material T800S/M21 and increase machining productivity.

COMPUTATIONAL CONTOUR OF MIXED MODE CRACK-TIP PLASTIC ZONE FOR ALUMINUM ALLOY 2024T351

The studies on mixed mode crack-tip plastic zones are one of the fundamental importance in describing the process of failure and in evaluation of the material life. The approach is also applied to predict crack initiation under mixed mode loading. The objective of this work is to study the contour of mixed mode crack-tip plastic zones, the minimum plastic zone radius (MPZR) and the direction of initial crack for aluminum alloy 2024T351 in Compact tension specimen by using Matlab software. This paper computed the shape, size of plastic zone at crack-tip and the minimum plastic zone radius with reference to the loading angle and stress intensity factor in linear elastic fracture mechanics regime for plane strain condition according to Von Mises yield criteria, the study is conducted for various loading angle. We found that the mixed mode loading (β = 60°) can lead to material fracture earlier than any mode loading.