Effect of Coating and Polishing of Cutting Tool on Machined Surface Quality in Dry Machining of Aluminium Alloy

Abstract

Surface quality is one of the major concerns in any machining process. To achieve the higher surface finish, mostly concentrated on machining parameter optimisation. This study has been carried out to study the effect of coating and polishing of flute surface of the solid carbide (WC-Co) endmill cutters on machined surface quality obtained during dry machining of Aluminium alloy 24345WP. Experiments were conducted on Aluminum workpieces with Ø6 mm 2 flute end- mill cutter with and without coating/polishing and their effect on surface quality studied for linear as well as areal surface roughness parameters using white light interferometery. The study concludes that polished flute tool, despite their non-sharp cutting edges, gives considerably better surface finish due to its lowering of chip tool friction. This was also supported by the results obtained from scanning electron microscopy of the cutting tool edge as well as optical microscopy of the obtained machined surface.

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

“…The current work is an optimization study of cutting conditions during dry end milling of AA5083, where the optimized geometry of the two-flute cutter is manufactured by a grinding 5-axis machine, as described in detail in Kechagias et al [17], and then the radial cutting depth, feed per tooth, and speed were tested in different dry cutting conditions. Note here that, in the literature, the majority of the research works utilized cutters from the market and not laboratorymade [35][36][37][38][39]. Therefore, the cutter geometry details were designed and optimized for the specified AA5083 alloy.…”