Study of the wear phenomenon of ceramic tools in the deburring process of objects made of aluminum and magnesium alloys

MINIATURA 7

Funding Organization: National Science Centre

Project title: Study of the wear phenomenon of ceramic tools in the deburring process of objects made of aluminum and magnesium alloys

Agreement number: DEC-2023/07/X/ST8/00665

Project implementation period: 05.10.2023 - 04.10.2024

Principal Investigator: dr inż. Jakub Matuszak

Project value: 47 924,00 PLN

Funds granted for Lublin University of Technology: 47 924,00 PLN

Abstract: Experimental research planned as part of the scientific activity meets the criteria of basic research, as it concerns the study of the wear phenomenon. The subject of the research will be tools: brushes with ceramic fibers used to remove burrs, as well as to remove surface defects (scratches, grooves, etc.) from objects made of magnesium and aluminum alloys. The edge condition of objects after machining in many cases requires further operations such as removing burrs, rounding or chamfering the edges. These requirements are related to maintaining the safety of assembly operations and further use of manufactured items. The additional operation, as a result of the impact of the tool on the workpiece, causes changes in the properties of the surface layer, both in the stereometric area (roughness, waviness) and in the physical area (microstructure, microhardness, residual stresses). The selected method of removing burrs and surface defects is brushing with ceramic tools.
The research planned in the project will contribute to obtaining knowledge about the wear of ceramic brushes during machining operations performed on objects made of magnesium and aluminum alloys.
Among the various forms of wear of tools used in machining, the most common form of wear is mechanical wear. Depending on the intensity of the machining process, mechanical wear may take two forms: abrasive and mechanical (chipping, cracks, catastrophic wear). The dominant form of wear of tools used in machining is abrasive wear, the analysis of which will be the main part of this scientific activity.
As part of the scientific activity, preliminary research on the wear phenomenon is planned using four types of ceramic brushes with different properties used in the process of removing burrs from objects made of magnesium alloys AZ31, AZ91 and aluminum alloy EN-AW7075. The main feature that distinguishes the four types of ceramic brushes planned for use in research is stiffness. The edges and surfaces of the manufactured samples will be brushed using brushes selected for testing.
The structure, surface topography, size and chemical composition of the ceramic fibers used will be determined before testing and at the wear stages specified in the research program. For this purpose, surface analysis will be performed with a scanning electron microscope. The linear and mass loss of ceramic brushes will also be determined. This will allow the selection of the optimal type of ceramic.