Session: 03-04-02: Advanced Machining and Finishing Processes

Paper Number: 113383

113383 - Finite Element Analysis and Process Parameters Optimization of AA2024 – T351 Alloy Machining Under Different Cooling Environments 

Aluminum alloys are popular in the industrial applications after steel and cast iron. The lower strength of Aluminum alloys can be improved by the addition of alloying elements and heat treatment related operations. AA 2024 – T351 is the alloy of aluminum with copper, and in addition tempering and stress relieving is performed as well to improve the strength related characteristics. AA2024-T351 is a high-strength aluminum alloy that has a combination of properties that make it particularly well-suited for use in aerospace and aircraft structural components. It is relatively lightweight, which makes it an attractive material for aircraft design, but it is also exceptionally strong and can withstand high stresses and loads. This combination of strength and lightness is particularly important in aerospace applications where weight is a critical factor. In addition to its strength and weight properties, AA2024-T351 is also highly resistant to corrosion. This makes it an ideal material for aircraft structures, which are exposed to a range of environmental conditions, including high altitude, extreme temperatures, and exposure to moisture and chemicals. There are several machining related challenges available when it comes to the machining performance of aluminum alloys. These challenges are linked with the chip formation due to sticky nature of material, strain hardening behavior and low thermal conductivity. Aluminum alloys can be difficult to machine due to the formation of long, stringy chips that can clog or damage cutting tools. This is because aluminum has a tendency to adhere to the cutting tool, which can lead to built-up edges and poor chip evacuation. Machining performance can be enhanced by the application of cutting fluids. The machining of AA2024-T351 can be carried out using various cooling methods, including dry, flood, and cryogenic cooling. Each of these methods has its advantages and disadvantages, and the choice of cooling method depends on various factors, such as the machining process parameters, tooling material and geometry, and workpiece material properties etc. The current study investigated the machining performance under the influence of different cooling environments such as dry, flood and liquid nitrogen based cryogenic. In this work, finite element based numerical modeling has been utilized to capture the behavior of machining AA2024-T351. The study varies cooling method, cutting speeds and cutting tool rake angle using Taguchi design of experiments. The output responses of cutting forces, cutting temperature, shear angle and chip compression ratio, and coefficient of friction were calculated. The findings were found in good agreement with the experimental data available in the literature.

Presenting Author: Salman Pervaiz RIT Dubai

Presenting Author Biography: Dr. Pervaiz received his PhD in Production Engineering from KTH Royal Institute of Technology, Sweden in 2015. While pursuing his PhD, Dr. Pervaiz has worked on a Swedish Industry (Accu-Svenska AB) supported project for the development of an advanced minimum quantity cooling lubrication (MQCL) system to facilitate the sustainable environment friendly machining of aeronautic titanium alloy (Ti6Al4V). Dr. Pervaiz’s research is mainly focused on the advanced topics of sustainable manufacturing. The research has made significant contributions in the field of environment friendly machining and associated numerical simulations. The research also incorporated novel computational fluid dynamic model to study the influence of cooling media and temperature distribution in the metal cutting process. The research outcomes have advanced the state of the art in the metal cutting to make machining more environment friendly in nature.

Dr. Pervaiz has taught several undergraduate and graduate level courses in the broader area of design and manufacturing. His teaching methodology incorporates the element of experiential learning by providing students the opportunities to gain ideas of multidisciplinary team work and hand on experience.

Authors:

Salman Pervaiz RIT Dubai
Sathish Kannan American University of Sharjah
Shafahat Ali University of Guelph