Effect of Tool Wear on Tri-Phase CVD Coated Carbide Tools Life while Turning Al6061

Abstract

Aluminum 6061 is a common alloy which is widely used in aerospace and yacht construction industry. Generally machining of aluminum alloys inherently generates high chip sticking on tool face and changes the tool edge geometry, which not only reduces tool life but also impairs the product surface quality. This study investigated the tool life and tool wear mechanisms besides evaluating surface roughness in various cutting conditions to attain finest possible surface with minimum tool wear. Turning experiments performed under dry orthogonal cutting of Al6061 using carbide CVD tri-phase coated inserts with constant depth of cut, various cutting speeds and feed rates. Insert’s flank and rake faces analyzed to assess wear mechanisms. Additionally Scanning electron microscope (SEM) employed to clarify different types of wear. Surface integrity and effect of built up edge in deviating surface roughness were studied in each cutting condition. Additionally results of experiments demonstrated that built up edge took over cutting edge and with sacrificing surface roughness, tool life increased by decreasing pace of abrasive wear propagation on flank face. According to these experiments the main reasons of flank wear were abrasive and adhesion of aluminum on tool face.

Artificial Intelligence Monitoring of Hardening Methods and Cutting Conditions and Their Effects on Surface Roughness, Performance, and Finish Turning Costs of Solid-State Recycled Aluminum Alloy 6061 Сhips

“…Mkoko and Abou-El-Hossein [35] observed the effects of depth of cut and feed rate at a fixed rotational speed on tool-wear rates and the resulting surface roughness of specimens turned with a diamond cutting tool from an aluminum alloy (6061-T6). Davoudinejad et al [36] investigated tool life and tool wear mechanisms, as well as evaluating surface roughness in various conditions of dry orthogonal cutting of Al6061. Davoudinejad et al [37] presented the effect of various cutting speeds in the turning of Al6061, with regard to different coatings.…”

“…Tootooni et al [39] used non-contact, vision-based online measurement for investigating surface finish in the turning of external steel and aluminum-alloy shaft diameters (4340 and 6061 grades). A number of studies [28][29][30][31][32][33][34][35][36][37][38][39] have investigated the turning of 6062 aluminum alloys. However, none accounted for the physical and mechanical properties attributed to the various conditions of the AA6061 workpiece on surface roughness in turning.…”