Investigations into Effect of Tool Wear on Surface Integrity in Dry Turning of Al6061

Abstract

Aluminum alloys offer number of various interesting mechanical and thermal properties which classified them among most commonly used lightweight metallic materials. 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 tool wear mechanism, surface integrity, and tool life in different cutting conditions to achieve finest surface roughness with considering longest tool life. Turning experiments performed under dry orthogonal cutting of Al6061 using carbide CVD tri-phase coated inserts. Constant depth of cut with different cutting speeds and feed rates utilized in experiments. Insert’s rake and flank faces investigated to figure out wear mechanisms. In addition scanning electron microscope (SEM) employed to evaluate various wear types. Surface integrity and effect of built up edge in surface roughness deviations studied in each cutting condition. Additionally, results of experiments demonstrated that built up edge covered tool cutting edge and increased tool life by decreasing pace of the abrasive wear propagation on the flank face with sacrificing surface roughness. All in all the main reason for flank wear was abrasive and adhesion of aluminum on tool faces.

Evaluation and Modeling of the Effect of Tool Edge Radius on Machined Surface Roughness in Turning UNS A92024-T351 Aluminum Alloy

“…Research has shown that tool wear has a significant effect on machined surface roughness. [21][22][23][24] For example, Jose et al 21 studied the effect of tool wear and surface roughness in turning D2 steel. They reported that as tool wear increases machined surface roughness increases considerably.…”