Akademik Veri Yönetim Sistemi
Journal of Manufacturing Processes, cilt.131, ss.2219-2229, 2024 (SCI-Expanded, Scopus)
The milling process of thin-walled structures will often face challenges such as increased vibrations and poor surface finishing due to reduced stiffness and damping properties of the workpiece. Shear thickening fluids (STFs), which have a shear-thickening (ST) characteristic (high viscosity upon stress and vibration), bring great solutions to some engineering problems, such as minimizing vibration generated by machining thin-walled components. In this study, we investigated the effectiveness of the STFs for vibration damping and surface quality improvement in milling U-shaped thin-walled aluminum workpieces. Rheological analysis demonstrated that the SiO2 concentration is the most influential factor on the ST properties of the STF. The modal analysis revealed that the STF-filled samples produced new frequency peaks and changed the system's natural frequency, resulting in improved stiffness and better suppressing vibration as opposed to the polyethylene glycol (PEG) filled and dry workpieces. Among the STFs, STF60, which had high concentrations of SiO2, showed excellent performance in milling conditions. Furthermore, the evaluation of surface roughness revealed a significant drop in roughness measurement (Ra) from 1.93 to 0.32 μm in milling operation 1 and 2.06 to 0.49 μm in milling operation 2 when the workpiece was filled with STF60, showing a notable improvement in surface quality. This study highlights the capability of STFs, particularly STFs with higher ST, to control vibrations in milling operations and improve the surface finishing of thin-walled structures.