Measurements of Forces and Selected Surface Layer Properties of AW-7075 Aluminum Alloy Used in the Aviation Industry after Abrasive Machining

Measurements of forces during machining, especially thin-walled structures typical of the aviation industry, are important in the aspect of instability caused by vibration. One of the last stages of manufacturing by machining is the finishing treatment and deburring of the product’s edges. Brushes with ceramic fibres are often employed in deburring, especially for large-sized elements specific to the aviation industry due to the possibility of automatic machining directly on machining centres. This study set out to analyse the effect of variable brushing conditions on axial forces and the selected surface layer properties of AW-7075 aluminium alloy. Experimental studies have examined factors such as surface roughness and topography, axial cutting force in ceramic brush treatment and surface free energy in the aspect of adhesive joints. The tested variable process parameters were the fibre material and the adjustment sleeve spring stiffness. Based on the tests, it was found that the axial force applied by the brush was more strongly connected with the spring stiffness rather than the type of bristle. For most cases, an increase in the value of free surface energy after brushing was observed compared to the initial machining which was milling.