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Optimisation of the aluminium compressor impeller machining process

Rattanakit, Rattanachai (2013)
Eng.D. thesis, University of Birmingham.

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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:Eng.D. thesis.
Supervisor(s):Soo, Sein Leung and Aspinwall, David K.
School/Faculty:Colleges (2008 onwards) > College of Engineering & Physical Sciences
Department:School of Medicine
Additional Information:

Full thesis embargoed until August 2017.

Work related to this thesis is published in

R. Rattanakit, S.L. Soo, D.K. Aspinwall, B. Haffner, Z. Zhang, D. Arnold, P. Harden
Evaluation of tool performance and hole quality when drilling C355 aluminium alloy using diamond coated and PCD drills
Proceedings of the 37th International MATADOR Conference, Manchester, United Kingdom, 25 -27 July 2012, pp.173-176.

Subjects:TN Mining engineering. Metallurgy
TS Manufactures
Institution:University of Birmingham
ID Code:4044
This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder.
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