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Number of results: 6
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Abstract

The paper presents the production problems related to casting using precision casting methods. The essential adverse effect of the casting

process is the presence of burrs understood as oversize material necessary to remove the next finishing operations. In addition, the surfaces

of the cast often characterized by a porous structure. One of the methods to improve the smoothness of the area proposed by the authors is

the use of vibro-abrasive finishing. This type of treatment is widely used in the treatment of finishing small objects as well as complex

shapes. Objects in the form of casting in the first step was treated with aggressive deburring polyester matrix abrasive media. The second

stage was polishing, with using smoothing porcelain media. The study evaluated the effect of vibro-abrasive machining typical cast on the

basic parameters of the geometric structure of the surface. Observations using optical microscope Nicon Eclipse MA 200 compared

changes in surface microstructure and the effect of deburring. Clearly we can say that vibro-abrasive machining an effective way

of reducing the size of burrs, smoothing and lightening the surface of objects made by casting.

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Authors and Affiliations

D. Bańkowski
S. Spadło
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Abstract

The article presents an example of finishing treatment for aluminum alloys with the use of vibration machining, with loose abrasive media in a closed tumbler. For the analysis of selected properties of the surface layer prepared flat samples of aluminum alloy PA6/2017 in the state after recrystallization. The samples in the first stage were subjected to a treatment of deburring using ceramic media. In a second step polishing process performed with a strengthening metal media. In addition, for comparative purposes was considered. only the case of metal polishing. The prepared samples were subjected to hardness tests and a tangential tensile test. As a result of finishing with vibratory machining, it was possible to remove burrs, flash, rounding sharp edges, smoothing and lightening the surface of objects made. The basic parameters of the surface geometry were obtained using the Talysurf CCI Lite - Taylor Hobson optical profiler. As a result of the tests it can be stated that the greatest reduction of surface roughness and mass loss occurs in the first minutes of the process. Mechanical tests have shown that the most advantageous high values of tensile strength and hardness are obtained with two-stage vibration treatment, - combination of deburring and polishing. Moreover the use of metal media resulted in the strengthening of the surface by pressure deburring with metal media.

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Authors and Affiliations

D. Bańkowski
S. Spadło
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Abstract

This article proposes to use abrasive waterjet cutting (AWJ) for deflashing, deburring and similar finishing operations in casting. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The experiments focused on the removal of external flash from elements made of EN-GJL-150 cast iron. The method employed for finishing was abrasive waterjet cutting. The tests were carried out using an APW 2010BB waterjet cutting machine. The form profiles before and after flash removal were determined with a Taylor Hobson PGI 1200 contact profiler. A Nikon AZ100 optical microscope was applied to observe and measure the changes in the flash height and width. The casting surface after finishing was smooth, without characteristic sharp, rough edges that occur in the cutting of objects with a considerable thickness. It should be emphasized that this method does not replace precise cutting operations. Yet, it can be successfully used to finish castings for which lower surface quality is required. An undoubted advantage of waterjet cutting is no effect of high temperature as is the case with plasma, laser or conventional cutting. This process is also easy to automate; one tool is needed to perform different finishing operations in order to obtain the desired dimensions, both internal and external.

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Authors and Affiliations

S. Bańkowski
S. Spadło
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Abstract

This paper presents a study of the hybrid electro-discharge mechanical machining BEDMM (Brush Electro-Discharge Mechanical Machining) with the application of a rotary disk brush as a working electrode. The discussed method enables not only an effective machining with a material removal rate of up to 300 mm3/min but also finishing (with the obtained roughness of Ra < 0.5 μm) of the surfaces of complex-shaped alloys with poor machinability. The analysis of the factors involved in the machining process indicates that its efficiency is determined by electrodischarge. The use of flexible working electrodes makes it possible to apply simple technological instrumentation and results in the simplicity of the process automation. The aim of the study was to obtain quantitative relationships between the parameters of brush electro discharge mechanical machining (BEDMM) and its effects. The presented experimental research results define the effect of the process input parameters on the performance and roughness of machined surfaces obtained for manganese cast steel.

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Authors and Affiliations

P.S. Młynarczyk
S. Spadło
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Abstract

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

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Authors and Affiliations

D. Bańkowski
ORCID: ORCID
S. Spadło
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Abstract

This article proposes these of vibratory machining to Ti-6Al-4V titanium alloy as finishing treatment. Titanium alloy was used in the aerospace industry, military, metallurgical, automotive and medical processes, extreme sports and other. The three-level three-factor Box-Behnken experiment examined the influence of machining time of vibratory machining, the type of mass finishing media used and the initial state of the surface layer on the mass loss, geometric structure of the surface, micro hardness and the optimal process parameters were determined. Considerations were given the surfaces after milling, after cutting with a band saw and after the sanding process. The experiment used three types of mass finishing media: polyester, porcelain and metal. Duration of vibratory machining treatment was assumed to be 20, 40, 60 minutes. The form profiles before and after vibratory machining were determined with the Talysurf CCI Lite - Taylor Hobson optical profiler. Future tests should concern research to carry out tests using abrasive pastes with a larger granulation of abrasive grains, to carry out tests for longer processing times and to determine the time after which the parameters of geometrical structure of the surface change is unnoticeable.

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Authors and Affiliations

D. Bańkowski
ORCID: ORCID
S. Spadło

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