Effect of the Geometry of Thin-Walled Aluminium Alloy Elements on Their Deformations after Milling

The aim of this paper is to analyse the effect of the selected geometric properties of thin-walled structures on post-machining deformations. In the study, EN AW-7075 T651 and EN AW-6082 T651 aluminium alloys were used to prepare specially designed thin-walled sample elements, i.e., elements with walls arranged in a semi-open and closed structure and with a dimension of 165 x 262 x 50.8 mm consisting of bottom and vertical stiffening walls and so-called ribs with a thickness of 1 mm. The measurements of the absolute deformations of the thin-walled bottom were performed with the use of a Vista coordinate-measuring machine by Zeiss with a PH10 head by Renishaw. Based on the obtained results, it was found that absolute deformation values were higher for walls arranged in a semi-open structure. It is related to a lower rigidity of the tested structure resulting from the lack of a stiffening wall, which is the so-called rib. Notwithstanding the geometry of the elements, greater absolute deformation values were recorded following conventional cutting methods. The use of high-speed cutting (HSC) provided positive outcomes in terms of minimising the deformation of thin-walled elements. Additionally, it was found that higher absolute deformations were obtained for EN AW-7075 T651 alloy.

Automated summary

This paper aims to analyze the effect of selected geometric properties on post-machining deformations of thin-walled structures. Through experiments on specially designed thin-walled sample elements, it was found that walls arranged in a semi-open structure had higher deformation values, and the use of high-speed cutting helped minimize the deformations of thin-walled elements. Moreover, the EN AW-7075 T651 alloy exhibited greater deformations.