The Study Of Surface Roughness and Tool Wear Analysis in Turning of Aluminum Using Different Advanced Cutting Tools (original) (raw)
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Machining of aluminum and its alloy is very difficult due to the adhesion and diffusion of aluminum, thus the formation of built-up edge (BUE) on the surface. The BUE, which affects the surface integrity and tool life significantly, affects the service and performance of the workpiece. The minimization of BUE was carried out by selection of proper cutting speed, feed, depth of cut, and cutting tool material. This paper presents machining of rolled aluminum at cutting speeds of 336, 426, and 540 m/min, the feeds of 0.045, 0.06, and 0.09 mm/rev, and a constant depth of cut of 0.2 mm in dry condition. Five cutting tools WC SPUN grade, WC SPGN grade, WC + PVD (physical vapor deposition) TiN coating, WC + Ti (C, N) + Al 2 O 3 PVD multilayer coatings, and PCD (polycrystalline diamond) were utilized for the experiments. The surface roughness produced, total flank wear, and cut chip thicknesses were measured. The characterization of the tool was carried out by a scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) pattern. The chip underface was analyzed for the study of chip deformation produced after machining. The results indicated that the PCD tool provides better results in terms of roughness, tool wear, and smoother chip underface. It provides promising results in all aspects.
This paper aims to scrutinize the effect of the cutting speed, feed rate and depth of cut on surface roughness, in turning of Aluminium (6061). The optimized values for these cutting parameters for minimum surface roughness are also obtained.Design of experiments (DOE) were conducted for the analysis of the influence of the turning parameters on the surface roughness by using Taguchi design and then followed by optimization of the results using Analysis of Variance (ANOVA) to find minimum surface roughness. The speed was identified as the most influential process parameter on surface roughness. The optimum surface roughness was reached when the feed rate and depth of cut were set as low as possible.
In the last decades, light materials, such as aluminum, are increasing their use in wide range of industrial applications. The growing use of aluminum encourages the study of its use under different production processes. In this sense, the present study shows an experimental investigation in turning of aluminum, with the use of dry and minimum quantity lubrication (MQL) system. To evaluate turning process, continuous bars was used. The process is evaluated taking the surface roughness as response variable. The cutting conditions include feed rate, cutting speed and the coolant flow rate. The work-piece material and its size, the cutting tool (HSS) and the depth of cut were kept constant for the study. It has been observed that a small amount of supply of coolant at the point of cutting, largely improves the surface finish. In many cases further amount of coolant administration has very little effect on the surface quality. Thus Minimum Quantity Lubrication (MQL) can achieve the required surface quality eliminating the problems of flood cooling.
UPB Scientific Bulletin, Series D: Mechanical Engineering
Precise knowledge of the machinability of aluminium is more and more important nowadays because aluminium alloys are used by many industries (e.g. the automotive, aerospace and defence industries) and therefore their importance is growing. Two of the most common indices of surface quality are Ra (average surface roughness) and Rz (surface height). However, these surface roughness parameters generally used in the industry do not properly characterise the expected behaviour of machined surfaces in operating conditions. The statistical parameters of surface roughness Rsk (skewness) and Rku (kurtosis) are more suitable to describe it. In this article the machinability of hypereutectic aluminium alloy (with silicon) parts was examined with the help of design of experiments (DOE). The examinations were carried out with different edge geometry diamond tools. The general and statistical values of machined surface roughness were analysed in detail. Conclusions were drawn on the effect of the...
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Aluminium alloys are increasingly used by the automotive and aerospace industries because of their numerous advantageous mechanical and chemical properties. Surface roughness is an essential characteristic of a machined surface. The most widespread aluminium alloy used in cutting is the die-cast type, alloyed with silicon. Industries prefer using two types of such alloys, the so-called eutectic and hypereutectic alloys. In this article the machinability of two die-cast aluminium alloys are examined with different edge-geometry tools (conventional-ISO, nonconventional-Wiper) and edge materials. The cutting experiments were carried out with design of experiment-DOE (the so-called central composite design-CCD). In the course of the examination three factors were altered (cutting speed-vc, m/min; feed-f, mm; depth of cut-a, mm), and the main surface roughness parameters used in the industries were taken as output parameters. The parameters of the manufactured surface roughness and their standard deviation in the case of different workpiece materials, tool materials and edge materials were analysed with statistical methods. Besides minimizing surface roughness, another important criterion of the manufacturing system (machine-tools-chuck-workpiece) is its surface roughness maintaining capacity, which was analysed with the coefficient of variation (CV).
Journal of Central South University, 2020
In the present study, the effect of reduction of cutting fluid consumption on the surface quality and tool wear was studied. Mathematical models were developed to predict the surface roughness using response surface methodology (RSM). Analysis of variance (ANOVA) was used to investigate the significance of the developed regression models. The results showed that the coefficient of determination values (R 2) for the developed models was 97.46% for dry, 89.32% for flood mode (FM), and 99.44% for MQL, showing the high accuracy of fitted models. Also, under the minimum quantity lubrication (MQL) condition, the surface roughness improved by 23%−44% and 19%−41% compared with dry and FM, respectively, and the SEM images of machined surface proved the statement. The prepared SEM images of tool rake face also showed a considerable decrease in adhesion wear. Built-up edge and built-up layer were the two main products of the adhesion wear, and energy-dispersive X-ray spectroscopy (EDX) analysis of specific points on the tool faces helped to discover the chemical compositions of adhered materials. By changing dry and FM to MQL mode, dominant mechanism of tool wear in machining aluminum alloy was significantly decreased. Breakage wear that led to early failure of cutting edge was also controlled by MQL technique.
Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061
EUREKA: Physics and Engineering, 2021
In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth o...
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