Browsing by Author "Gil Del Val, Alain"
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Item Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)(2020-02-01) Veiga, Fernando; Gil Del Val, Alain; Suárez, Alfredo; Alonso, Unai; Tecnalia Research & Innovation; FABRIC_INTELIn the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.Item Characterization of Inconel 718® superalloy fabricated by wire Arc Additive Manufacturing: effect on mechanical properties and machinability: effect on mechanical properties and machinability(2021-09) Alonso, Unai; Veiga, Fernando; Suárez, Alfredo; Gil Del Val, Alain; Tecnalia Research & Innovation; FABRIC_INTELWire and Arc Additive Manufacturing has the potential to become an appropriate technique to produce large complex-shaped metallic parts. However, a post-processing machining operation is necessary to reach the final geometry. In this work, Inconel 718 walls were manufactured in a monitored environment and their microstructure and mechanical properties were characterised. Then, slot milling operations were performed to investigate the influence of cutting speed and machining direction. The conclusions drawn from this article can be used as a guide for a correct definition of strategies and milling parameters. It was observed that at higher cutting speeds a better surface quality and lower torques are obtained. Moreover, the main novelty of this work is that is shows the influence of the anisotropy of WAAM-Inconel 718 on its machinability. Milling along the torch's travel direction offers better dimensional tolerance values with lower cutting torques, being more favourable than machining in the building direction.Item Oversizing Thread Diagnosis in Tapping Operation(2021-03-25) Gil Del Val, Alain; Veiga, Fernando; Penalva, Mariluz; Arizmendi, Miguel; Tecnalia Research & Innovation; FABRIC_INTELAutomotive, railway and aerospace sectors require a high level of quality on the thread profiles in their manufacturing systems knowing that the tapping process is a complex manufacturing process and the last operation in a manufacturing cell. Therefore, a multivariate statistical process control chart, for each tap, is presented based on the principal components of the torque signal directly measured from spindle motor drive to diagnosis the thread profile quality. This on-line multivariate control chart has implemented an alarm to avoid defected screw threads (oversized). Therefore, it could work automatically without any operator intervention assessing the thread quality and the safety is guaranteed during the tapping process.Item Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations(2021-06-24) Veiga, Fernando; Gil Del Val, Alain; Penalva, Mari Luz; Pereira, Octavio; Suárez, Alfredo; López de Lacalle Marcaide, Luis Norberto; Tecnalia Research & Innovation; FABRIC_INTELA low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force model based on a commercial control-supported chip breaking function without external vibration devices in the boring operations. The model was fitted by conventional boring measurements and was validated by vibration boring experiments with different ranges of amplitude and frequency. The average prediction error is around 10%. The use of a commercial function makes the model more attractive for the industry because there is no need for intrusive vibration sensors. The low-frequency assisted boring (LFAB) operations foster the chip breakage. Finally, the model is generic and can be used for different cutting materials and conditions. Roughness is improved by 33% when vibration conditions are optimal, considered as a vibration amplitude of half the feed per tooth. This paper presents, as a novelty, the analysis of low-frequency vibration parameters in boring processes and their effect on chip formation and internal hole roughness. This has a practical significance for the definition of a methodology based on the torque model for the selection of conditions on other hole-making processes, cutting parameters and/or materials.Item Thread Quality Control in High-Speed Tapping Cycles(2020-02) Gil Del Val, Alain; Veiga, Fernando; Suárez, Alfredo; Arizmendi, Mikel; Tecnalia Research & Innovation; FABRIC_INTELThread quality control is becoming a widespread necessity in manufacturing to guarantee the geometry of the resulting screws on the workpiece due to the high industrial costs. Besides, the industrial inspection is manual provoking high rates of manufacturing delays. Therefore, the aim of this paper consists of developing a statistical quality control approach acquiring the data (torque signal) coming from the spindle drive for assessing thread quality using different coatings. The system shows a red light when the tap wear is critical before machining in unacceptable screw threads. Therefore, the application could reduce these high industrial costs because it can work self-governance.Item Threading Performance of Different Coatings for High Speed Steel Tapping(2020-05-01) Gil Del Val, Alain; Veiga, Fernando; Pereira, Octavio; Lopez De Lacalle, Luis Norberto; Tecnalia Research & Innovation; FABRIC_INTELThreading holes using tapping tools is a widely used machining operation in the industry. This manufacturing process involves a great tool immersion in the part, which involves both friction and cutting. This makes the use of coatings critical to improving tool life. Four coatings are used based on Physical vapor deposition (PVD) technology—TiN, TiCN, TiAlN and TiAlN+WC/C are compared to uncoated tool performance. The effect of various coatings on the life ofM12 _ 1.5 tapping tools during threading of through holes 20 mm deep, in GG25 casting plates, dry and applying cutting speed of 50 m/min. The end-of-life criterion has been established based on a cutting torque of 16 N-m. Taking the uncoated tap as a basis for comparison, it is observed that coatings based on PVD technologies increase tool life doubling in the most advantageous case with the TiAlN coating. PVD type coatings provide better protection towear at cylindrical area of the tool, where the thread profile is finished, than uncoated taps. The teeth located in the cone-cylinder transition zone of the taps suffer the most wear regardless of the coating. However, taps coated with TiAlN+WC/C wear level values is lowest of all the coatings tested, which indicates a strong reinforcement in these teeth.