Matuszak Jakub, Kawalec Andrzej, Gdula Michał
Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, Nadbystrzycka 38D, 20-618 Lublin, Poland.
Department of Manufacturing Techniques and Automation, Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, Wincentego Pola 2, 35-959 Rzeszów, Poland.
Materials (Basel). 2024 Dec 21;17(24):6267. doi: 10.3390/ma17246267.
The paper presents the results of an analysis of the effect of brushing on the edge condition of workpieces with complex geometric shapes, formed during milling, on a five-axis DMU 100 monoBLOCK machining center. A set of EN-AW 7075 aluminum alloy specimens with curvilinear edges requiring multi-axis machining was prepared. The change of edge condition after the milling process was realized using Xebec tools with flexible ceramic fibers. The effects of brush fiber type and parameters related to tool design were analyzed. Different brushing strategies were employed on the five-axis machining center. It was shown that, for curvilinear edges, there were different effects for concave and convex edges depending on the employed tool strategy, including the type of tool, its configuration, and its orientation towards the workpiece. For a lead angle of β = 0°, the machined edge was characterized by variable chamfer widths, in spite of maintaining other machining parameters constant. The use of a lead angle β > 0 produced a stable edge with repeatable characteristics. The range of fiber interaction increased with increasing the lead angle and fiber working length.
