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 (τ_mean). 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 g_h 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 g_σ = 1.1 mm. The positron mean lifetime τ_mean 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.

Trochoidal Milling and Neural Networks Simulation of Magnesium Alloys

This paper set out to investigate the effect of cutting speed v_c and trochoidal step s_tr 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: v_c = 400-1200 m/min and s_tr = 5-30%. The results demonstrate a significant effect of cutting data modification on the parameter under scrutiny-the increase in v_c 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.