Optimisation of the aluminium compressor impeller machining process

Download Statistics

Downloads

Downloads per month over past year

Rattanakit, Rattanachai (2013). Optimisation of the aluminium compressor impeller machining process. University of Birmingham. Eng.D.

Preview

Rattanakit13EngD.pdf
PDF - Accepted Version
Download (16MB)

Abstract

The research involved the optimisation of various machining operations for the manufacture of automotive turbocharger impellers. Phase 1 work comprised a capability study of the Al-Si C355 impeller machining process within Doncasters Sterling. The results highlighted that both C $_p$ and C $_{pk}$ values were generally above the automotive industry standard of 1.66 and that current processes were capable of producing parts to specification. Benchmark testing of TiN coated WC and PCD tooling against uncoated WC was undertaken in Phase 2 experiments. While the PCD tools showed significant improvement, the TiN coated tools were inferior in terms of thrust force, torque and workpiece surface roughness when compared against the uncoated WC tools. Phase 3 research evaluated the performance of advanced diamond like carbon (DLC) coatings against WC when blind-hole drilling C355 and reaming 6082-T6 aluminium alloys. Benefits in terms of extended tool life and reduced material adhesion/BUE were observed when drilling and reaming using the commercial Graphit-iC™ coating. The performance of CVD diamond coated and PCD tools were also assessed with the latter showing lower wear rates with negligible workpiece adhesion/BUE compared to WC in both drilling and reaming experiments. The former however failed catastrophically at high cutting speeds during drilling.

Type of Work:

Thesis (Doctorates > Eng.D.)

Award Type:

Doctorates > Eng.D.

Supervisor(s):