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Investigating the Effects of Cutting Methods for Aluminum Metallic Foams
Investigación de los efectos de los métodos de corte para espumas metálicas de aluminio
DOI:
https://doi.org/10.15446/ing.investig.110998Keywords:
Aluminium foam metals, wire EDM cutting, secondary operations, laser cutting (en)espumas metálicas de aluminio, operaciones secundarias, corte por láser, corte EDM por hilo (es)
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The quality of foam metal materials, which are commonly used in industrial applications due to their unique properties, increasingly relies on secondary processing. Metal foams are produced as plates or in the desired shape via direct or indirect foaming. Given their intended use, the primary challenge lies in determining how to cut them with the necessary precision and join them with sufficient strength. However, the most difficult aspect is cutting them in the required shapes and combining them with fixed or removable securing mechanisms. This work involved cutting two sample types: a 10 mm thick AlMgSi foam with a density of 0.5 g/cm³, using a laser cutter, and a 19 mm thick AlMgSi sandwich structure with a 1 mm thick aluminum outer plate via wire electric discharge machining (WEDM). In addition, the results of manual cutting and angle grinding, which are often utilized in production, were analyzed through scanning electron microscopy. Under certain suboptimal conditions, laser cutting caused aluminum to dissolve into the cavities and form burrs beneath the cutting edge. In contrast, when accurate and undistorted cellular architecture is essential, WEDM is very efficient, even though it is 200 times slower than laser cutting. Hand-sawing caused cellular fractures and frequent dispersion, so it is suitable for applications that do not necessitate accuracy.
La calidad de los materiales de espuma metálica, que se utilizan comúnmente en aplicaciones industriales debido a sus propiedades únicas, depende cada vez más del procesamiento secundario. Las espumas metálicas se producen en placas o en la forma deseada mediante espumación directa o indirecta. Dado su uso previsto, el principal desafío radica en determinar cómo cortarlas con la precisión necesaria y unirlas con la fuerza suficiente. Sin embargo, el aspecto más difícil es cortarlas en las formas requeridas y combinarlas con mecanismos de sujeción fijos o removibles. Este trabajo involucró el corte de dos tipos de muestras: una espuma de AlMgSi de 10 mm de grosor con una densidad de 0.5 g/cm³, utilizando un cortador láser, y una estructura tipo sándwich de AlMgSi de 19 mm de grosor con placa exterior de aluminio de 1 mm de grosor mediante mecanizado por electroerosión por hilo (WEDM). Además, los resultados del corte manual y del rectificado angular, que a menudo se utilizan en la producción, se analizaron a través de microscopía electrónica de barrido. En ciertas condiciones subóptimas, el corte láser hizo que el aluminio se disolviera en las cavidades y formara rebabas debajo del borde de corte. En contraste, cuando una arquitectura celular precisa y no distorsionada se hace esencial, el WEDM es muy eficiente, a pesar de ser 200 veces más lento que el corte láser. El corte manual causó fracturas celulares y dispersión frecuente, por lo que es adecuado para aplicaciones que no requieran precisión.
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Copyright (c) 2024 Altug BAKIRCI, Tayfun SIGIRTMAC, Mustafa Cemal CAKIR, Agah UGUZ
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