Available online at www.sciencedirect.

com
Available online at www.sciencedirect.com

ScienceDirect 
ScienceDirect 
Available
Available online
Procedia atatwww.sciencedirect.com
Manufacturing
online 00 (2017) 000–000
www.sciencedirect.com
Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
ScienceDirect
ScienceDirect 
Procedia Manufacturing 13 (2017) 81–88
Procedia Manufacturing 00 (2017) 000–000
www.elsevier.com/locate/procedia

Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June
Manufacturing Engineering Society
2017, International Conference
Vigo (Pontevedra), Spain2017, MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
Parametric analysis of the Ultimate Tensile Strength in dry
Parametric
Manufacturing analysis
Engineering ofInternational
Society the Ultimate Tensile
Conference 2017,Strength in28-30
MESIC 2017, dry June
machining
2017, of UNS
Vigo A97075
(Pontevedra), Spain Alloy
machining of UNS A97075 Alloy
Costing modelsC. Bermudo*,
C.for capacity
Bermudo*,
F.J.optimization
Trujillo, M. Herrera,
F.J. Trujillo, M. Herrera,
L. Sevilla 4.0: Trade-off
in Industry
L. Sevilla
between used capacity Universityand operational efficiency
Department of Manufacturing Engineering, University of Malaga. C/ Dr. Ortiz Ramos s/n, Málaga E-29071, Spain.
Department of Manufacturing Engineering, of Malaga. C/ Dr. Ortiz Ramos s/n, Málaga E-29071, Spain.

A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb

Abstract
Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Aluminium alloys (mainly 2XXX and 7XXX b
series) have
Unochapecó, been traditionally
89809-000 used
Chapecó, SC, in the industry in the manufacture of structural
Brazil
Aluminium alloys (mainly 2XXX and 7XXX series) have been traditionally
parts in aircrafts, due to their excellent ratio density-mechanical used in the isindustry
properties. Machining commonly in theused
manufacture of structural
in the manufacture of
parts in aircrafts, due to their excellent ratio density-mechanical properties. Machining is commonly used
these parts. In addition, the actual trend is machining in dry, due to environmental and economic reasons. Under these conditions, in the manufacture of
these
surfaceparts. In addition,
integrity becomes theone
actual trend
of the is machining
most importantinquality
dry, due to environmental
requirements and economic
applicable to machined reasons.
parts.Under these and
The micro conditions,
macro-
Abstract
surface integrity
geometrical becomes
properties one of of
analysis the the
mostdryimportant
machined quality requirements
surface applicable
as a function to cutting
of the machined parts. Theismicro
parameters widely andstudied.
macro-
geometrical
Notwithstanding,properties
there isanalysis
a lack ofof the dry
research machined
in the surfacetoas
field dedicated theaphysicochemical
function of theproperties.
cutting parameters
In this paperisthewidely studied.
feed influence
Under
on the concept
Notwithstanding,
the ultimate thereof
tensile is a"Industry
lack for
strength UNS 4.0",
of research inproduction
A97075 the field
(Al-Zn) processes
dedicated
alloy to the will
turned in drybe pushedproperties.
physicochemical
is presented, toas be increasingly
a firstIn interconnected,
this paper the
approximation feed
to theinfluence
study of
on the
the ultimate
information
influence of tensile
based onstrength
a real
the cutting for UNS
time
parameters onA97075
basis and,
this (Al-Zn) alloy
necessarily,
mechanical turnedmore
much
property. in dryefficient.
is presented, as a first
In this approximation
context, to the study of
capacity optimization
the2017
goes
© influence
beyond of
thethetraditional
The Authors. cutting parameters
Published aim byof on this
capacity
Elsevier mechanical
B.V. property.
maximization, contributing also for organization’s profitability and value.
© 2017 The
Indeed,
Peer-review leanAuthors.
under Publishedand
management
responsibility by
of Elsevier
continuous
the B.V. committee
scientific improvement
of the approaches suggest
Manufacturing Engineeringcapacity
Societyoptimization instead of
International Conference
© 2017 The Authors.
Peer-review under Published by
responsibility ofElsevier B.V. committee of the Manufacturing
the scientific Engineering Society International Conference
2017.
maximization. The study of capacity optimization and costing models is an important research
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference topic that deserves
2017.
2017.
contributions from both the practical and theoretical perspectives. This paper presents and discusses a mathematical
Keywords: Aluminum Alloys; UNS A97075; Dry Machining; Ultimate Tensile Strength.
model forAluminum
Keywords: capacityAlloys;
management based
UNS A97075; Dryon differentUltimate
Machining; costing models
Tensile (ABC and TDABC). A generic model has been
Strength.
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might hide operational inefficiency.
1. Introduction
© 2017 The Authors. Published by Elsevier B.V.
The sustainable
Peer-review
manufacturing
under responsibility
has three
of the scientific
important
committee
core
of thecore
ideas: theEngineering
Manufacturing
economy, Society
the environment and
International and
society.
Conference
The sustainable
Nowadays, manufacturing
the sustainability has beenhasmainly
three important
oriented to reduceideas: the economy,
the environment the of
impact environment society.
the production systems,
2017.
Nowadays,
developing theandsustainability
promoting the has been
noun mainly oriented
as green to reduce
production. the environment
Nevertheless, this impact of thesystem
production production systems,
sidelines the
developing and promoting the noun as green production. Nevertheless, this
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency
production system sidelines the

1. Introduction
* Corresponding author. Tel.: +34 951 952 427.
* Corresponding
E-mail address:author. Tel.: +34 951 952 427.
bgamboa@uma.es
The cost
E-mail of idle
address: capacity is a fundamental information for companies and their management of extreme importance
bgamboa@uma.es
in modern©production
2351-9789 systems.
2017 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©under
2351-9789
Peer-review ways: tons of production,
2017responsibility
The Authors. Published
of available
by Elsevier
the scientific B.V.hours
committee of manufacturing,
of the Manufacturing etc.Society
Engineering The International
management of the 2017.
Conference idle capacity
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
the Manufacturing Engineering Society International Conference 2017.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
10.1016/j.promfg.2017.09.012
82 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88
2 C. Bermudo / Procedia Manufacturing 00 (2017) 000–000

functionality of the products obtained [1,2].

So, it is necessary to consider the efficiency of the process in sake of the performance and add the Efficiency
Tetrahedron concept: functional, energetic, environmental and economic. The four elements are interconnected with
a center common element: the global efficiency [3,4].
One of the industrial sectors most involved in the change towards the application of the new concept of High
Performance Manufacturing has been the Aeronautical industry. In recent years, the aeronautical production systems
have been paying particular attention to clean production, even when this green production entails the assumption of
a loss of economic performance, especially in highly energy-efficient contexts [5-7].
In addition, the manufacturing of aircrafts involves high safety levels. There are elements that required narrow
margins of deviation in the design requirements, not only in their geometry but also in terms of physicochemical
properties that mark their behavior in service [8,9].
Many of the high-demand parts are produced by machining processes like milling, turning and drilling. Aluminium
and/or titanium alloys are used for strategic parts that can be structurally sensitive and are high-committed to the flight
safety of the aircraft. In the particular case of aluminum alloys, which are the ones selected for the analysis presented
in this paper, the increase in environmental performance has been established through the application of processes in
which cutting fluids are removed (dry turning) [10-12].
These alloys have been used due to their excellent weight/physicochemical properties/cost. These materials meet
the severe requirements for the strength required in structural elements of aircraft [13,14]. However, machining
processes and its dry application can adversely affect the performance in service of the parts or components
manufactured, decreasing the functional performance of the process, through the loss of quality or the surface integrity
of the parts. [10,13,15]. The surface integrity can be defined as the properties that exhibit the surface of a material
after any forming process and that are acquired and/or modified during the accomplishment of the same [16].
These surface properties can be analyzed from two points of view: geometric properties, with its micro and macro
scale consideration, and physicochemical properties (Table 1), being able to improve or worsen the functional
performance of the shaped element. The geometric properties have been widely studied [17-20], unlike the
physicochemical properties [21,22]. Present work focus on the physicochemical characteristics, in particular in the
mechanical properties, studding the influence of the feed, f, in the Ultimate Tensile Strength (UTS) of an aluminium
alloy 97075 T6. This aluminum alloy is often used in the aircraft industry (7000 series, Al-Zn) along with the 2000
series (Al-Cu) [13,14].

Table 1. Levels for the evaluation of the surface integrity [16]

Geometric Physicochemical
Microgeometric Macrogeometric
Surface roughness Cylindricity Microhardness variation
Microcraks Concentricity Fatigue strength
Macrocraks Roundness UTS
Particle adhesion Parallelism Residual stresses
Others Others Others

Almost all manufacturing processes generate residual stresses. They can be large enough to cause local creep or
plastic deformation, both at the macroscopic and microscopic levels, which impacts negatively in the functional
performance of the affected component. The mechanical properties considered are affected, among other
circumstances, by machining processes. Changes in these properties are generally linked to the metallurgical state in
which the machined part remains after the forming process. During machining, the surrounding material is elastically
deformed to preserve dimensional continuity, and thus, residual stresses are created. The UTS can be significantly
influenced by these stresses. The residual stresses can be defined as the stresses that remain in a material or body after
a manufacturing process in the absence of external forces or thermal gradients. Different studies show that mainly the
micro-geometric deviations and the residual stresses can affect other mechanical properties like fatigue and tensile
strength, important parameters in this kind of workpieces [23,24]. So, this study starts with the analysis of the feed
 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88 83
C. Bermudo / Procedia Manufacturing 00 (2017) 000–000 3

influence on the UTS, being part of the current studies that are being carried out of superficial integrity of dry machined
samples of this alloys in the University of Malaga (UMA – TEP-933) and University of Cadiz (UCA – TEP-027), in
order to establish the methodology and expand the study with other analysis in the future.

2. Materials and Methods

To evaluate the influence of the cutting parameters in the UTS of the material selected, different test samples were
machined and tested in a tensile-compression testing equipment.
First, the specimen tests samples were obtained from UNS A97075 T6 Al-Zn alloy bars of diameter 20 mm and
length 220 mm. The alloy composition tested is shown in Table 2.¡Error! No se encuentra el origen de la referencia.

Table 2. Composition of aluminium-zinc alloy UNS A97075 (% weight).

Zn Mg Cu Cr Al Rest
6.30 2.23 1.77 0.21 88.42 1.07

The cylindrical samples for tensile testing (Fig. 1) were dry turned following the standard UNE-EN ISO 6892:2017
“Metallic materials. Tensile testing. Part 1: Method of test at room temperature (ISO 6892-1: 2016” [25], using a
turning CNC center.

Fig. 1. Specimen geometry for tensile test according UNE-EN ISO 6892-1:2017.

The tools used in the tests were uncoated WC-Co inserts (ISO DCMT 11T308F2), (Fig. 2a). To ensure identical
conditions in all the tests, a new cutting tool was used in the finishing process. The cutting speed (vc) and the depth of
cut (ap) were stablished at 80 m/min and 1 mm respectively for all the tests performed. These values are within the
range used in machining this alloy, in particular for the aeronautical applications. Present work analyses the influence
of the feed (f) in the UTS due to its proven influence in the micro and macro-geometric parameters related to the
superficial integrity, like Ra or shape deviations [9]. For each cutting parameters combination (Table 2), five samples
were machined following the standard for tensile tests [26] (20 samples). Also, the chip generated in the process was
collected for further analyses (Fig. 2b).

Fig. 2. (a) Cutting tool setup; (b) Chip generated in one of the tests.
84 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88
4 C. Bermudo / Procedia Manufacturing 00 (2017) 000–000

Table 3. Cutting parameters.

vc (m/min) 80 80 80 80
f (mm/r) 0.05 0.10 0.20 0.30
ap (mm) 1 1 1 1

In order to analyze the evolution of the surface integrity at the microgeometric level and its relationship with the
mechanical property studied (UTS), a roughness analysis was performed for all the samples after the turning process,
using a surface roughness tester (Mitutoyo Surftest SJ-210), Fig. 3. The parameters used to evaluate the microscale
deviations were the arithmetical mean roughness (Ra), widely used in the industry as surface quality parameter, and
the average maximum peak to valley of five consecutive sampling lengths (Rz). Rz is also considered due to the
influence of the peak and valleys in crack generation, affecting the mechanic properties of the workpiece.

Fig. 3. Roughness measurement setup

Fig. 4. (a) Sample after tensile test; (b) preparation of tensile test.

Next, tensile tests were carried out to evaluate the UTS for all the machined samples. A tensile-compression testing
equipment MTS Insight Electromechanical Testing Systems, that can apply loads up to 300 kN, was used. The
equipment has a control software and a data collection system that allows the registration of the test outputs, in periods
of 0.5 s in this case study, as the loads (kN), extension (mm), stress (MPa) and deformation (mm/mm). So, a graphical
 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88 85
C. Bermudo / Procedia Manufacturing 00 (2017) 000–000 5

representation of the UTS of each sample can be obtained.

Knowing that the standard UNE-EN ISO 6892-1:2017 specifies that in case that only the UTS is studied, the
deformation speed must not exceed 0.008 s-1, the speed for the tensile test is stablished in 2.25 mm/min, according to
the machine specifications (Fig. 4).

3. Results

After the turning process of each sample is completed, the chip is collected and the macro-morphology is analyzed.
Fig. 5 shows the chip morphology for the different feeds implemented. As in previous studies [11,23,24], chip
morphology shows a general trend to form continuous chip (Fig. 5) and chip nest (Fig. 2b) that may affect the final
surface quality. This is due to the high Zn content of the alloy, which provides it with a high plasticity [28]. Only for
the highest value of f (0.30 mm/r) the chip becomes shorter and segmented. The high cutting force and compression
stress at this high feed value results in a more likely overcoming of the shear limit.
Also, Fig. 6 and 7 shows the influence of the feed rate on the microgeometrical deviations, evaluated through Ra
and Rz. It can be appreciated a general tendency to increase the values of Ra and Rz when the feed range increases.
This increment is clearly significant from feed rates of 0.10 to 0.20 mm/r. For the low range values (0.05 and 0.10
mm/r), Ra and Rz remain practically constant. Increasing the feed rate to 0.20 and 0.30 mm/rev there is an increase in
Ra of a 180% and 620% respectively, and an increase in Rz of a 230% and a 458% respectively. As a result, the chip
nest morphology cannot be related to the Ra changes. There is no tendency to increase Ra values when chip nests are
present. So, the higher the feed rates, the higher the roughness is and can be estate that the feed rate is a decisive
parameter if the superficial integrity of the samples must be considered, being in concordance with previous studies
[29].

Fig. 5. Chip macro-geometrical evolution as a function of feed.

Fig. 6. Ra average comparison for all the feed rates considered.

86 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88
6 C. Bermudo / Procedia Manufacturing 00 (2017) 000–000

Fig. 7. Rz average comparison for all the feed rates considered.

Subsequently the tensile tests are carried out and the load and displacement data from every sample are processes
to obtain different graphics and study the influence of the f in the UTS. The UTS average are compared to establish
the influence of the parameter analysed (Fig. 8). Also, the UTS obtained from the non-machined bar is compared with
the rest of the machined samples. It can be appreciated a 7 - 9% increment of the UTS between the machined and non-
machined samples. This is due to the residual stresses that appear during the turning process. These residual stresses
are mainly compressive and superficial, which increment the UTS [16]. Notwithstanding, it is difficult to differentiate
the feed influence in the machined samples due to its small deviation. Considering the error bars present in the graphics
of Fig. 8, it can be estate that the UTS present values of the same order for the different feed rates considered, although
other studies present a direct relation between f and the UTS [30].

Fig. 8. UTS average comparison and stress-strain curve for all the feed rates considered.

Results show that there is possible to establish a clear UTS tendency to increase with the feed rate for the parameters
of vc and ap considered. Notwithstanding, is not possible to establish a clear relation between the increase of the feed
rate and the UTS because, in these case studies, the variation is within the deviation of the results. Also, it is not
possible to established a relation between the UTS and Ra or Rz, in concordance with [30]. Even for the f = 0.30 mm/r,
where several vibrations are present during the turning process (Fig. 9), the UTS variation is minimal (Fig. 8). On the
other hand, there is an implicit relation between the feed rate and the superficial integrity, as seen with the Ra and Rz
parameters. Different studies with higher increments in the feed rate, vc and ap are necessary to be able to estate the
influence of the feed rate in the UTS as in other studies [30], and continue the study of the cutting parameters in other
mechanical properties (Table 1)
 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88 87
C. Bermudo / Procedia Manufacturing 00 (2017) 000–000 7

Fig. 9. Deformation due to vibration during turning process.

4. Conclusions

From the results of the analysis of the effect of the dry machining process parameters in the UTS of aluminium
UNS A97075 T6 alloy, mainly focused on the variation and influence of the feed, the following conclusions are drawn:

 The chip morphology has a general tendency to form chip nests independently of the f range applied.
 Ra and Rz values have a general tendency to increase with f. This increment is most appreciable with high feed
applied, while in the range of low feed the differences are less appreciable.
 An increase in the UTS value was observed after the samples are machined, regardless of the f value applied. This
is due to the residual tensions caused by the turning process that cause compression stresses on the surface of the
machined specimen.
 The results obtained from the tensile tests do not allow a direct relationship between UTS and the feed speed. The
variation of the UTS can be contained in the dispersion of the results obtained.
 A direct relation between the parameters used to evaluate the microgeometric deviations of the surface (Ra and Rz)
with the UTS variation was not possible to establish.

It should be pointed that it is necessary to increase the combinations of the cutting parameters used (vc and ap) to
establish definitive conclusions. The study is presented as a first step in the analysis of the cutting parameters on the
mechanical properties and complements the studies on other mechanical properties (such as fatigue resistance) that
are currently being carried out in the UMA, as well as to the analysis carried out that examine the influence other
output variables (microgeometric deviations, macrogeometric, tool wear, chip morphology, cutting forces, etc.) in the
dry machining of these alloys (2xxx and 7xxx) with the aim of improve the performance of this type of processes.

Acknowledgements

The authors thank University of Malaga – Andalucía Tech Campus of International Excellence for its contribution
on this paper and to the Spanish Ministry of Economy and Competitiveness for financial support of the project
DPI2016-78476-P.

References

[1] M. Lieder, A. Rashid, J. Clean. Prod. 115 (2016) 36–51.

[2] D. Dornfeld. Green Manufacturing, first ed., Springer US, Boston, USA, 2013.
[3] F. Apostolos, P. Alexios, P. Georgios, S. Panagiotis, C. George, Proc. CIRP. 7 (2013), 628–633.
[4] J. Salguero Gómez, “Análisis, evaluación y propuestas de mejora del rendimiento del mecanizado de alta velocidad de aleaciones de aluminio
de interés en la industria aeronáutica”, PhD Thesis, University of Cádiz, 2013.
[5] F. Pusavec, P. Krajnik, J. Kopac, J. Clean. Prod. 18 (2010), 174–184.
[6] F. Pusavec, D. Kramar, P. Krajnik, J. Kopac J. Clean. Prod. 18 (2010) 1211–1221.
[7] A. D. Jayal, F. Badurdeen, O. W. Dillon, I. S. Jawahir, CIRP J. Manuf. Sci. Tech. 2 (2010) 144–152.
[8] G. Murray, C. V. White, W. Weise, Introduction to Engineering Materials, CRC Press-Taylor & Francis Group, London, UK, 2007.
88 C. Bermudo et al. / Procedia Manufacturing 13 (2017) 81–88
8 C. Bermudo / Procedia Manufacturing 00 (2017) 000–000

[9] F. J. Trujillo, L. Sevilla, M. Marcos, Adv. Mech. Eng. 6 (2015) 382435–382435.

[10] E. M. Rubio, A. M. Camacho, J. M. Sánchez-Sola, M. Marcos, J.Mat. Process. Tech. 162–163 (2005) 682–689.
[11] J. Salguero, M. Batista, M. Sánchez-Carrilero, M. Álvarez, M. Marcos, Adv. Mech. Res. 107 (2010) 9–14.
[12] P. W. Marksberry, I. S. Jawahir, Int. J. Mach. Tool. Manu. 48 (2008) 878–886.
[13] M. S. Carrilero, R. Bienvenido, J. M. Sánchez, M. Álvarez, A. González, M. Marcos, 42 (2002).
[14] J. M. Sánchez, E. Rubio, M. Álvarez, M. A. Sebastián, M. Marcos, J. Mater. Process. Tech. 164–165 (2005) 911–918.
[15] A. Gómez-Parra, M. Álvarez-Alcón, J. Salguero, M. Batista, M. Marcos, Wear. 302 (2013) 1–2, 1209–1218.
[16] Á. Gómez Parra, “Estudio de la influencia del mecanizado en el rendimiento funcional de aleaciones de aluminio de uso estratégico en la
industria aeronáutica”, PhD Thesis, University of Cádiz, 2016.
[17] J. Salguero, J. M. Sanchez, M. A. Sebastian, M. Sanchez-Carrilero, M. Marcos, Annals of Daaam & Proceedings. 1 (2010).
[18] M. Marcos-Bárcena, M. A. Sebastián-Pérez, J. P. Contreras-Samper, M. Sánchez Carrilero, M. Sánchez-López, J. M. Sánchez-Sola, 162-163
(2005) 644-648.
[19] M. A. Sebastian, J. M. Sanchez-Sola, M. S. Carrilero, J. M. Gonzalez, M. Alvarez, M. Marcos, J. Manu. Sci. Prod. 4 (2002) 181–188.
[20] Z. Pu, J. C. Outeiro, A. C. Batista, O. W. Dillon, D. A. Puleo, I. S. Jawahir, Procedia Engineer. 19 (2011) 282–287.
[21] Y. Choi, Int. J. Fatigue. 78 (2015) 46–52.
[22] M. Olsson, V. Bushlya, J. Zhou, J.-E. Ståhl, Procedia CIRP. 45 (2016) 103–106.
[23] G. S. Schajer. Practical residual stress measurement methods, fisrt ed., John Wiley & Sons, Ltd, UK, 2013.
[24] S. Faghidian, D. Goudar, G. Farrahi, D. J. Smith, J. Strain Anal. Eng. 47 (2012) 254–264.
[25] AENOR. AENOR: Norma UNE-EN ISO 6892-1:2010. Available at: http://www.aenor.es/. AENOR.
[26] AENOR. UNE-EN ISO 6892-1. Metallic materials - Tensile testing, Part 1: Method of test at room temperature (ISO 6892-1:2009). AENOR,
Madrid, 2010.
[27] M. S. Carrilero, M. Marcos, J. Mech. Behav Mater. 7 (1996) 179–194.
[28] F. Trujillo, L. Sevilla, F. Martín, C. Bermudo, Appl. Sci-Basel. 7 (2017) 132.
[29] F. J. Trujillo Vilches, “Análisis paramétrico del mecanizado en seco de la aleación UNS A97075”, PhD Thesis, University of Málaga, 2013.
[30] A. Gómez-Parra, F. J. Puerta, E. I. Rosales, J. M. González-Madrigal, M. Marcos, Procedia Engineer. 63 (2013) 796–803.