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The aim of this study is to investigate the impact of machining parameters on the deflection of a cutting tool (i.e., end mill) in the milling of a surface with a curvilinear profile. Test samples were made of aluminium alloy EN AW-7075 T651. Experiments were conducted using the Gocator 2530 laser line profile sensor for real-time measurement of dynamic tool displacement with an inspection speed up to 10 kHz at resolution ranging from 0.028 to 0.054 mm. Response surface methodology was used. Five main technological factors were analysed: cutting speed, feed per tooth (cutting parameters), amplitude, term (curvilinear profile parameters), and the number of flutes (end mill parameter). Obtained data were filtered and visualised as 3D plots. The results showed that cutting speed and amplitude had the greatest impact on tool deflection, while feed per tooth also played a significant role in process stability. In particular, the use of tools with a higher number of flutes led to a considerable reduction in tool deflection, confirming their positive effect on the stability of the machining process. These findings may serve as a basis for the optimisation of machining parameters by taking into account the dynamic deformation of cutting tools.

This article presents the results of a study of the properties of epoxy adhesives in an adhesive joint. The study analysed changes in Young’s modulus values as a function of the rigidity of the adhesive and the type of joined material. The values of Young’s modulus values were determined on the thickness of the adhesive joint using the nanoindentation method and in a tensile test of dumbbell shape sample for the adhesive material. The obtained results were analysed in terms of changes to the values of Young’s modulus of the adhesive as a function of the distance from the joined material–adhesive phase boundary and compared to the adhesive material. Zones were distinguished in the layer of the adhesive joint—adjacent to the wall and the core, with different values of Young’s modulus. Conclusions were drawn, indicating the relationship between the adhesive joint thickness and the increase in the value of Young’s modulus. Significant differences were found in the values of Young’s modulus of the adhesive joint compared to Young’s modulus of the adhesive in the form of plastic.

This paper presents the results of a study of adhesive joints, focused on the heterogeneity of the properties of the adhesive material in the adhesive joint. The main objective of the study was to determine potential differences in the material properties of adhesive joints made with selected structural adhesives. Due to the impact of the joined material on the adhesive during the curing of the joint as well as the impact of phenomena occurring during the curing of the adhesive, the properties of the adhesive joint may vary along the thickness of the joint. Determining the differences in material properties over the thickness of the adhesive bond is important for more accurate prediction of adhesive bond strength in FEM simulations. In order to observe changes in the material properties of bonds, nanoindentation tests have been carried out on eight adhesive joint bonds made with common structural adhesives used to join sheets of aluminium alloy or corrosion-resistant steel. Basing on the achieved test results, load/unload curves were developed for imprints at characteristic spots of the joints. Distinct differences in the achieved average force value were observed for imprints located in the wall-adjacent zone and in the centre of the adhesive joint; this can be interpreted as areas of the joint with different material structures of higher or lower density of imperfections or porosities. Differences in the load/unload curves for ‘rigid’ and ‘flexible’ adhesives were analysed. The summary includes a conclusion that an adhesive joint is characterised by heterogeneous properties along its thickness.

This article is an evaluation of the phenomena occurring in adhesive joints during curing and their consequences. Considering changes in the values of Young’s modulus distributed along the joint thickness, and potential changes in adhesive strength in the cured state, the use of a numerical model may make it possible to improve finite element simulation effects and bring their results closer to experimental data. The results of a tensile test of a double overlap adhesive joint sample, performed using an extensometer, are presented. This test allowed for the precise determination of the shear modulus G of the cured adhesive under experimental conditions. Then, on the basis of the research carried out so far, a numerical model was built, taking the differences observed in the properties of the joint material into account. The stress distribution in a three-zone adhesive joint was analyzed in comparison to the standard numerical model in which the adhesive in the joint was treated as isotropic. It is proposed that a joint model with three-zones, differing in the Young’s modulus values, is more accurate for mapping the experimental results.

The paper presents the results of nanoindentation testing, carried out along the thickness of the adhesive joint joining sheets of aluminum alloy. The purpose of the tests was to determine changes in the Young’s modulus in the joint resulting from the active impact of the joined aluminum alloy sheets on the adhesive during curing of the adhesive bond. Structural changes that take place during curing of the joint, especially in the boundary zone, can have a significant impact on the adhesive properties and consequently, on the adhesive joint strength. The Young’s modulus of the adhesive (Ek) in the joint assumes variable values as the distance from the connections changes. This phenomenon is called the apparent Young’s modulus. The problem is to define the size of the boundary zone in which the value of Ek significantly differs from the value in the so-called core. Based on the obtained results of experimental tests, a numerical model was built taking into account the observed differences in the properties of the joint material. The stress distribution in the adhesive joint, single-lap connection with the three-zone adhesive joint, was analyzed in comparison to the classical numerical model in which adhesive in the adhesive joint is treated as isotropic in terms of rigidity.

In this study, the correlations between milling conditions—namely, the cutting tool feed direction relative to the rolling direction, the milling type, the coolant application, as well as the cutting speed—and the surface residual stress of a selected aluminum alloy (2024 T351) were investigated. Determining the type and magnitude of residual stress is of paramount importance as this stress is among the primary causes of post-machining strain of thin-walled components. On the basis of the experimental results, it was found that all factors analyzed significantly affect the residual stress state. Specifically, milling in the parallel direction induces lower residual tensile stress compared to milling in the perpendicular direction. Analogously, up-milling yields lower tensile residual stress than down-milling, and flood cooling leads to lower tensile residual stress than MQL. It was clearly confirmed that as cutting speed increases, tensile residual stress also increases, but only up to a certain threshold; once the high-speed cutting regime is reached, tensile residual stress begins to decrease. Consequently, the proper selection of milling parameters is a crucial consideration for optimizing machining processes and minimizing machining-induced residual stress.