Dry machining of aluminum–silicon alloy using polished CVD diamond-coated cutting tools inserts

Arumugam, Prabhu U.; Malshe, Ajay P.; Batzer, Stephen A.

doi:10.1016/j.surfcoat.2005.08.127

Cited by 89 publications

(40 citation statements)

References 10 publications

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“…It was found that the quantity of dust generated during the machining process depends on the cutting tool geometry, the workpiece materials and the cutting parameters used (Ref [27][28][29][30]35). Therefore, it is necessary to analyse the effect of these factors on dust emission.…”

Section: Resultsmentioning

confidence: 99%

Effects of Speeds, Materials, and Tool Rake Angles on Metallic Particle Emission During Orthogonal Cutting

Khettabi

Songmené

Masounave

2009

J. of Materi Eng and Perform

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Dry high speed machining has been proposed as a viable and cost-effective process in metal cutting industries. However, it produces fine and ultra-fine metallic particles, also referred to as dust, which can be harmful to the machine-tool operator. The risk associated with exposure to metallic particles increases as the particle size decreases. For machining processes, little data exist on the size and distribution of dust generated during the shaping of materials. In order to reduce or eliminate the generation of these particles, it is necessary to understand how and under which conditions they are formed, as well as to be able to make predictions. In this study, the effects exerted by tool geometry, material, and machining parameters on dust emission were studied experimentally in order to understand the mechanisms of dust generation and to develop a predictive model. The particle sizes studied include the PM2.5 (particles with aerodynamique diameter below 2.5 lm) and a distribution of nanoparticles varying in size from 10 nm to 10 lm. Using dry machining and reducing the amount of dust generated should improve the air quality in machine shops in addition to helping protect the environment.

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Section: Resultsmentioning

confidence: 99%

Effects of Speeds, Materials, and Tool Rake Angles on Metallic Particle Emission During Orthogonal Cutting

Khettabi

Songmené

Masounave

2009

J. of Materi Eng and Perform

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“…120 The degree of difficulty in performing dry machining is a function of the cutting process, as well as of the work and tool materials put into use. 121 In order to carry out the range of dry drilling, reaming, tapping, and end-milling operations successfully on aluminum alloys, it is essential to use tools with suitable coating systems and to apply a minimum quantity of lubricant. This is especially true when the L/D ratio, or the ratio of hole depth to diameter, is greater than three.…”

Section: Dry Drilling Of Aluminum Alloysmentioning

confidence: 99%

Machinability aspects of heat-treated Al-(6-11)%Si cast alloys :

Zedan¹

2010

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“…The chip friction on the rake face and the cutting 44,46) tested the PCD (physical vapor deposition) tools, the unpolished CVD (chemical vapor deposition) tools, and the polished CVD tools, and found that polished CVD tools produce fewer particles than PCD and unpolished CVD tools (Ref 44,46). Under these conditions, according to the frictionrelated mechanisms of particle emission described in Fig.…”

Section: Analytical Modeling Of Particle Emissionmentioning

confidence: 99%

Modeling of Particle Emission During Dry Orthogonal Cutting

Khettabi

Songmené

Zaghbani

et al. 2009

J. of Materi Eng and Perform

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Because of the risks associated with exposure to metallic particles, efforts are being put into controlling and reducing them during the metal working process. Recent studies by the authors involved in this project have presented the effects of cutting speeds, workpiece material, and tool geometry on particle emission during dry machining; the authors have also proposed a new parameter, named the dust unit (D u ), for use in evaluating the quantity of particle emissions relative to the quantity of chips produced during a machining operation. In this study, a model for predicting the particle emission (dust unit) during orthogonal turning is proposed. This model, which is based on the energy approach combined with the microfriction and the plastic deformation of the material, takes into account the tool geometry, the properties of the worked material, the cutting conditions, and the chip segmentation. The model is validated using experimental results obtained during the orthogonal turning of 6061-T6 aluminum alloy, AISI 1018, AISI 4140 steels, and grey cast iron. A good agreement was found with experimental results. This model can help in designing strategies for reducing particle emission during machining processes, at the source.

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Dry machining of aluminum–silicon alloy using polished CVD diamond-coated cutting tools inserts

Cited by 89 publications

References 10 publications

Effects of Speeds, Materials, and Tool Rake Angles on Metallic Particle Emission During Orthogonal Cutting

Effects of Speeds, Materials, and Tool Rake Angles on Metallic Particle Emission During Orthogonal Cutting

Machinability aspects of heat-treated Al-(6-11)%Si cast alloys :

Modeling of Particle Emission During Dry Orthogonal Cutting

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