Machinability of Rolled Aluminum using Advanced Coated Cutting Tools and its Characterization (original) (raw)
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As the aviation along with automobile industrial units require high finish with precise surface, so the machining process tends to focus about the machined part surface integrity having lower cost with less tool wear. Aluminium and Al-alloys are the most suitable ones due to their peculiar properties for these requirements.. Here the dry turning of pure aluminium has been attempted using advanced tools like uncoated WC, WC + TiN, WC + Ti(C,N) +Al2O3 and PCD by using speed range from 400 to 700 m/min along with variation in feed rate. The highly précised Surtonic S-128 roughness tester was used to measure surface roughness while SEM (Scanning Electron Microscope) was utilised to observe chip shear band formation and tool wear. The Elemental mapping technique was used to analyse adhesion. The different results show that PCD tools are more suitable than other coated tools for the machining of Al.
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The use of aluminum alloys in manufacturing industry has increased significantly in recent years. This is because primarily to their ability to combine lightness and strength in a single material. Concomitant to this growth, the machining of aluminum alloys has enormously increased in volumetric proportions-so that the chip volume represents up to 80 % of the original volume of the machined material in certain segments of the industry, like aerospace. In this context, knowledge of the characteristics of machinability of aluminum alloys is essential to provide industry and researchers with information that allows them to make the right decisions when they come to machining this fantastic material. The purpose of this review is to compile relevant information about the characteristics of machinability of aluminum alloys into a single document.
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The aluminium alloys are used by the automotive, aerospace industries increasingly because of their numerous advantageous mechanical and chemical properties. Surface roughness measurements are essential in characterization of the features 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 reinforced with silicon. In this article the cutting capacities of two die-cast aluminium alloys are examined. 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 deviation in case of di...
International Journal of Refractory Metals and Hard Materials, 2009
An investigation has been undertaken to study the compatibility of cutting materials in dry machining of aluminium and Al-Si alloys. Mono or multilayer coated carbide tools with a top coating of TiC, TiN, TiAlN, Al 2 O 3 , TiB 2 , MoS 2 etc. on WC-Co inserts already made a major breakthrough in dry machining of ferrous materials. But in contrast dry machining of aluminium and Al-alloys is a great challenge. But wide application of aluminium different parts has increased the need to find out the correct cutting tool. Experimental results of turning test, SEM pictures and chip morphology investigation of the cutting tool after machining clearly reveals the inefficiency of TiC, TiN, TiB 2 , Al 2 O 3 , and AlON in dry machining of aluminium. This is because of the formation of very large amount of metal built-up in both rake and flank surface leading to high magnitude of cutting forces and high roughness of the work-piece during machining. The natural diamond and polycrystalline diamond (PCD) can be used as a cutting tool, when the required shape is attached on the edge/tip for machining non-ferrous materials. But both of them are limited for finishing cut because of high cost. So CVD diamond coated tool is a better option to machine these materials. CVD diamond coated tool was free from built-up edge formation leading to clean cut, low magnitude of cutting forces and improved surface finish of the work-piece. However, performances of the diamond tool depend mainly on adhesion of the diamond coating with the carbide substrate.