Dry Machinability of Aluminum Alloys

2005 ◽  
Author(s):  
Iqbal Shareef ◽  
Manikandan Natarajan ◽  
Oyelayo O. Ajayi
Keyword(s):  
Tool Wear ◽  
Aluminum Nitride ◽  
Surface Finish ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Finish Temperature ◽  
Titanium Aluminum ◽  
Coated Carbide ◽  
Titanium Aluminum Nitride

Adverse effects of the use of cutting fluids and environmental concerns with regard to cutting fluid disposability is compelling industry to adopt Dry or near Dry Machining, with the aim of eliminating or significantly reducing the use of metal working fluids. Pending EPA regulations on metal cutting, dry machining is becoming a hot topic of research and investigation both in industry and federal research labs. Although the need for dry machining may be apparent, most of the manufacturers still consider dry machining to be impractical and even if possible, very expensive. This perception is mainly due to lack of appropriate cutting tools that can withstand intense heat and Built-up-Edge (BUE) formation during dry machining. The challenge of heat dissipation without coolant requires a completely different approach to tooling. Special tooling utilizing high-performance multi-layer, multi-component, heat resisting, low friction coatings could be a plausible answer to the challenge of dry machining. In pursuit of this goal Argonne National Labs has introduced Nano-crystalline near frictionless carbon (NFC) diamond like coatings (DLC), while industrial efforts have led to the introduction of composite coatings such as titanium aluminum nitride (TiAlN), tungsten carbide/carbon (WC/C) and others. Although, these coatings are considered to be very promising, they have not been tested either from tribological or from dry machining applications point of view. As such a research program in partnership with federal labs and industrial sponsors has started with the goal of exploring the feasibility of dry machining using the newly developed coatings such as Near Frictionless Carbon Coatings (NFC), Titanium Aluminum Nitride (TiAlN), and multi-layer multicomponent nano coatings such as TiAlCrYN and TiAlN/YN. Although various coatings are under investigation as part of the overall dry machinability program, this extended abstract deals with a systematic investigation of dry machinability of Aluminum 6061 and 2024 using uncoated carbide, TiN coated carbide, and TiAlN coated carbide inserts. Central Composite Design (CCD) is used to study the effect of speed, feed, depth of cut, workpiece material, and cutting tool material on the resulting forces, surface finish, temperature, chip morphology and tool wear. Each of the machining responses is measured and compared under 15 different machining conditions. Results from CCD experiments have been used to develop linear and logarithmic models for forces (Fx, Fy, Fz, & Fr) surface finish (Ra), and temperature. Furthermore, chip morphology and tool wear have also been compared. From the comparison of forces, surface finish, temperature, chip morphology, tool wear and the corresponding statistical models, it is clear that in general TiAlN results in lower forces, better surface finish, greater fragmented chips, and lesser tool wear.

Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Titanium-aluminum nitride film growth and related chemistry using dimethylamino-based precursors

2001 ◽  
Vol 385 (1-2) ◽  
pp. 66-73 ◽  
Author(s):  
J.P Endle ◽  
Y.-M Sun ◽  
J Silverman ◽  
N Nguyen ◽  
A H. Cowley ◽  
...  
Keyword(s):  
Aluminum Nitride ◽  
Film Growth ◽  
Nitride Film ◽  
Titanium Aluminum ◽  
Titanium Aluminum Nitride

Dry Machining of Brass Using Titanium Carbonitride (TiCN) Coated Tool

2013 ◽  
Vol 372 ◽  
pp. 495-500
Author(s):  
Tasnim Firdaus Ariff ◽  
Mohd Syahidan Kamarudin ◽  
Mohd Amiruddin Haron
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Cutting Parameters ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Machining ◽  
Wear Rates ◽  
Optimum Cutting ◽  
The Cost

Dry machining is environmentally friendly, clean and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Wear rates, tool wear intensities and material removal rates (MRR) of TiCN coated tools using both dry and traditional wet machining on brass were studied with the aim in finding the optimum cutting condition from four different cutting speeds (207, 279, 372 and 498 m/min) with two sets of cutting parameters; depth of cut and feed rate (d = 0.1 mm, f = 0.2 mm/rev and d = 0.2 mm, f = 0.4 mm/rev). Temperatures at the tool-chip interface were measured to analyze the effects of temperature rise during dry machining. Cost analysis on machining cost per piece between dry and wet machining was performed. The optimum cutting condition for wet and dry machining of brass using TiCN coated cutting tool was found to be 498 m/min at d = 0.2 mm, f = 0.4 mm/rev. The tool tip temperature obtained from dry machining did not influence tool wear since the temperature rise is quite similar to the wet machining temperatures. The machining for the dry machining reduced to about 25-76% per piece when compared with wet machining.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

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