Effect of the Technological Parameters of Milling on Residual Stress in the Surface Layer of Thin-Walled Plates.

The production of thin-walled elements, especially those with large overall dimensions, poses numerous technological and operational problems. One of these problems relates to the machining-induced strain of such elements resulting from residual stress generated during the machining process. This study investigates the effect of the technological parameters of milling on residual stress in the surface layer of thin-walled plates made of aluminum alloy EN AW-2024 T351 for aerospace applications. The results have shown that residual stress increases with the cutting speed only to a certain point, reaching the maximum value at vc = 750 m/min. At a cutting speed vc = 900 m/min, residual stress significantly decreases, which probably results from the fact that the milling process has entered the High-Speed Cutting range, and this inference agrees with the results obtained for the cutting force component. Residual stress increases with the feed per tooth, while the relationship between residual stress and milling width is the same as that established for residual stress and variable cutting speed. Positive tensile stress is obtained in every tested case of the milling process. The results have also shown that the induced residual stress affects the strain of machined thin-walled parts, as proved by the strain results obtained for milled thin walls.

Non-Equilibrium Crystallization of Monotectic Zn-25%Bi Alloy under 600 g.

This study investigated the influence of supergravity on the segregation of components in the Zn-Bi monotectic system and consequently, the creation of an interface of the separation zone of both phases. The observation showed that near the separation boundary, in a very narrow area of the order of several hundred microns, all types of structures characteristic for the concentration range from 0 to 100% bismuth occurred. An additional effect of crystallization in high gravity is a high degree of structural order and an almost perfectly flat separation boundary. This is the case for both the zinc-rich zone and the bismuth-rich zone. Texture analysis revealed the existence of two privileged orientations in the zinc zone. Gravitational segregation also resulted in a strong rearrangement of the heavier bismuth to the outer end of the sample, leaving only very fine precipitates in the zinc region. For comparison, the results obtained for the crystallization under normal gravity are given. The effect of high orderliness of the structure was then absent. Despite segregation, a significant part of bismuth remained in the form of precipitates in the zinc matrix, and the separation border was shaped like a lens. The described method can be used for the production of massive bimaterials with a directed orientation of both components and a flat interface between them, such as thermo-generator elements or bimetallic electric cell parts, where the parameters (thickness) of the junction can be precisely defined at the manufacturing stage.