Analysis of Geometric Surface Structure and Surface Layer Microhardness of Ti6Al4V Titanium Alloy after Vibratory Shot Peening.

This article presents an analysis of the impact of vibratory shot peening on the surface roughness and physical properties of the Ti6Al4V titanium alloy surface layer after milling. The elements of machine parts and structures made of titanium alloys are often exposed to variable loads during operation. Therefore, it is advisable to apply methods that enhance functional properties and increase the durability of interacting components. Increasing the operational durability of such elements can be achieved by vibratory shot peening. Variable amplitudes A = 24; 33; 42; 51; 60 mm and times t = 1; 7; 13; 19; 25 min were applied. It has been demonstrated that it is possible to achieve a threefold reduction in the roughness parameter, Sa = 0.344 µm, compared with milling, Sa = 0.95 µm. An increase in Smr(c) areal material ratio was observed after vibratory shot peening compared with milling. It has been shown that amplitude has a greater impact on the increase in hardening of the surface layer gh compared with time. The highest rate of change in surface roughness and thickness of the hardened layer was achieved at a vibratory shot-peening time of t = 13 min. The greatest thickness of the hardened layer, exceeding 200 µm, was obtained after shot peening with an amplitude of A = 60 mm.

Investigation of the Impact of High-Speed Machining in the Milling Process of Titanium Alloy on Tool Wear, Surface Layer Properties, and Fatigue Life of the Machined Object.

This article presents the results of experimental research on the effect of high-speed machining (HSM) in the milling process on the tool wear, surface layer properties, and fatigue life of objects made of Ti-6Al-4V titanium alloy. Titanium alloys are widely used in many industries due to their high strength-to-density ratio, corrosion resistance, and resistance to dynamic loads. The experiment was conducted on a vertical three-axis machining centre, Avia VMC800HS. The influence of increased cutting speeds on the average values and amplitudes of the total cutting force components and the surface roughness of the machined workpiece was determined. Variable cutting speeds vc = 70; 130; 190; 250; 310 m/min were applied. The impact of HSM on machinability indicators, such as the microhardness of the surface layer, the distribution of residual stresses, and the fatigue life of the samples after milling, was analysed. The thickness of the hardened layer varied from 20 to 28 micrometres. The maximum compressive residual stress Ϭm = 190 MPa was achieved at the speed of vc = 190 m/min. A significant influence of increased cutting speeds on tool wear was demonstrated. The longest tool life (t = 70 min) was obtained for low cutting speeds (conventional) vc = 70 m/min.

Influence of Slide Burnishing Parameters on the Surface Layer Properties of Stainless Steel and Mean Positron Lifetime.

This paper presents the results of an experimental study on the impact of slide burnishing on surface roughness parameters (Sa, Sz, Sp, Sv, Ssk, and Sku), topography, surface layer microhardness, residual stress, and mean positron lifetime (τmean). In the study, specimens of X6CrNiTi18 stainless steel were subjected to slide burnishing. The experimental variables were feed and slide burnishing force. The slide burnishing process led to changes in the surface structure and residual stress distribution and increased the surface layer microhardness. After slide burnishing, the analyzed roughness parameters decreased compared with their pre-treatment (grinding) values. The slide burnishing of X6CrNiTi18 steel specimens increased their degree of strengthening e from 8.77% to 42.74%, while the hardened layer thickness gh increased after the treatment from about 10 µm to 100 µm. The maximum compressive residual stress was about 450 MPa, and the maximum depth of compressive residual stresses was gσ = 1.1 mm. The positron mean lifetime τmean slightly yet systematically increased with the increase in burnishing force F, while an increase in feed led to changes of a different nature.

Analysis of the Effectiveness of Removing Surface Defects by Brushing.

The paper presents the results of a study on the effectiveness of removing surface defects by brushing. Damage to machine components usually begins on their surface or in the surface layer area. This determines the development of methods, conditions, and process parameters that will positively affect the stereometric and physical properties of the surface layer. Experiments were conducted in which surface defects were generated on a specially designed test stand. By controlling the load and speed of the defect generator it was possible to affect the geometry, depth, and width of the surface defect. A FEM simulation of the brushing treatment was carried out in order to determine the effect of fibers passing through a surface defect in the form of a groove with a small depth and width. It was shown that for certain conditions of brushing treatment, surface defects could be removed effectively. Moreover, the microhardness of the surface layer after the brushing process was analyzed. Changes in microhardness due to brushing reached up to 50 µm for EN AW-2024 aluminum alloy and up to 150 µm for AZ91HP magnesium alloy. The results demonstrated that brushing was an effective method for strengthening the surface layer and that the value of strengthening in the area of defects depended on the effectiveness of their removal.

Non-Destructive Detection of Real Defects in Polymer Composites by Ultrasonic Testing and Recurrence Analysis.

This paper presents results of ultrasonic non-destructive testing of carbon fibre-reinforced plastics (CFRPs) and glass-fibre reinforced plastics (GFRPs). First, ultrasonic C-scan analysis was used to detect real defects inside the composite materials. Next, the composite materials were subjected to drilling in the area of defect formation, and measured forces were used to analyse the drilling process using recurrence methods. Results have confirmed that recurrence methods can be used to detect defects formed inside a composite material during machining.

Selected Properties of Self-Compacting Concrete with Recycled PET Aggregate.

In this paper, the issue of self-compacting concrete (SCC) with the addition of polyethylene terephthalate (PET) recycled aggregate is addressed. The PET utilized was a waste fraction in the PET-bottle-recycling process. The implementation of waste in concrete mixes has a positive impact on their environmental and social profile; however, technical requirements are not necessarily met. In this investigation, PET was used as a substitute for fine aggregate in quantities ranging from 0 to 20% in increments of 5%. Both the flow properties of SCC mixes and the hardened SCC properties (compressive strength, splitting tensile strength, modulus of elasticity, and Poisson ratio) were investigated. Additionally, non-destructive tests (ultrasound and sclerometric) were performed to determine the correlation curves. The research revealed that both the flow properties and the parameters of the hardened concrete deteriorated with the PET content. Concrete with 20% PET replacement did not meet the self-compacting requirements and its compressive strength decreased by almost 50%. However, it was noted that replacing fine aggregate with PET aggregate in the amount of 5% did not significantly alter the concrete parameters and could be an attractive alternative to traditional concretes. Based on non-destructive testing, correlation curves were constructed that could be applicable to the future quality assessment of self-compacting concretes with recycled PET aggregate.

Influence of Semi-Random and Regular Shot Peening on Selected Surface Layer Properties of Aluminum Alloy.

This paper attempts to compare regular shot peening (RSP) and semi-random shot peening (SRSP). A characteristic of the first method is that the peening elements hit the treated surface in sequence, with a regular distance maintained between the dimples. The other method (SRSP) is a controlled modification of the shot-peening process, which is random by nature. The shot-peening method used in this study differs from conventional shot peening (shot blasting and vibratory shot peening) in that it allows controlled and repeatable determination of the configuration and distribution of impacts exerted by the peening element on the workpiece surface, which makes the process more repeatable and easier to model. Specimens of EN-AW 7075 aluminum alloy were used for testing. The following variables were used in the experiments: ball diameter, impact energy, and distance between the dimples. Microhardness distribution in the surface layer, 2D surface roughness, and surface topography were analyzed. FEM simulations of the residual stress distribution in the surface layer were performed. It has been found that regular shot peening results in reduced surface roughness, while semi-random shot peening leads to higher surface layer hardening.

Measurements of Forces and Selected Surface Layer Properties of AW-7075 Aluminum Alloy Used in the Aviation Industry after Abrasive Machining.

Measurements of forces during machining, especially thin-walled structures typical of the aviation industry, are important in the aspect of instability caused by vibration. One of the last stages of manufacturing by machining is the finishing treatment and deburring of the product's edges. Brushes with ceramic fibres are often employed in deburring, especially for large-sized elements specific to the aviation industry due to the possibility of automatic machining directly on machining centres. This study set out to analyse the effect of variable brushing conditions on axial forces and the selected surface layer properties of AW-7075 aluminium alloy. Experimental studies have examined factors such as surface roughness and topography, axial cutting force in ceramic brush treatment and surface free energy in the aspect of adhesive joints. The tested variable process parameters were the fibre material and the adjustment sleeve spring stiffness. Based on the tests, it was found that the axial force applied by the brush was more strongly connected with the spring stiffness rather than the type of bristle. For most cases, an increase in the value of free surface energy after brushing was observed compared to the initial machining which was milling.

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys.

This paper set out to investigate the effect of cutting speed vc and trochoidal step str modification on selected machinability parameters (the cutting force components and vibration). In addition, for a more detailed analysis, selected surface roughness parameters were investigated. The research was carried out for two grades of magnesium alloys-AZ91D and AZ31-and aimed to determine stable machining parameters and to investigate the dynamics of the milling process, i.e., the resulting change in the cutting force components and in vibration. The tests were performed for the specified range of cutting parameters: vc = 400-1200 m/min and str = 5-30%. The results demonstrate a significant effect of cutting data modification on the parameter under scrutiny-the increase in vc resulted in the reduction of the cutting force components and the displacement and level of vibration recorded in tests. Selected cutting parameters were modelled by means of Statistica Artificial Neural Networks (Radial Basis Function and Multilayered Perceptron), which, furthermore, confirmed the suitability of neural networks as a tool for prediction of the cutting force and vibration in milling of magnesium alloys.