The Effects of Cutting Parameters on the Characteristics of Chip and Cutting Force in High-Speed Milling of A6061 Aluminum Alloy
Main Article Content
Abstract
This paper studied the formulation of chip in high-speed milling of A6061 aluminum alloy. To verify the chip formation and microstructure, experimental results of the chip morphology were derived. The capture by SEM of experimental results showed that high-speed milling produced serrated chip. From the deformation of various zone of chip surface, we can conclude that the chip deformation directly effect on the friction at tool and chip contact during in high-speed milling for A6061 aluminum alloy. In this study, the effects of cutting parameters on the width and structure of free-surface of the chip were examined. The deformability of material and interaction at the tool-chip contact were also identified. The experimental results showed that high-speed milling produced serrated chip, which was significantly affected by the friction at tool and chip contact.
Keywords
High-speed milling of A6061 aluminum alloy, serrated chip, structure of free-surface of the chip
Article Details
References
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[2]. S. Ekinovi and J. Kopa, A contribution to the understanding of chip formation mechanism in high-speed cutting of hardened steel, Achiev. Mech. Mater. Eng. (2002) 1-4.
[3]. Y. Ozcatalbas, Chip and built-up edge formation in the machining of in situ A14C3-Al composite, Mater. Des. 24 (2003) 215-221.
[4]. G. Sutter, Chip geometries during high-speed machining for orthogonal cutting conditions,” Int. J. Mach. Tools Manuf. 45 (2005) 719-726.
[5]. S. Dolinsek, S. Ekinović, and J. Kopač, A contribution to the understanding of chip formation mechanism in high-speed cutting of hardened steel, J. Mater. Process. Technol. 157–158 (2004) 485–490.
[6]. H. K. Toenshoff and B. Denkena, Basics of Cutting and Abrasive Processes. Berlin, Heidelberg: Springer Berlin Heidelberg, (2013).
[7]. C. Wang, Y. Xic, L. Zheng, Z. Qin, D. Tang, and Y. Song, Research on the Chip Formation Mechanism during the high-speed milling of hardened steel, Int. J. Mach. Tools Manuf. 79, (2014) 31-48.
[8]. J. Barry and G. Byrne, The Mechanisms of Chip Formation in Machining Hardened Steels, J. Manuf. Sci. Eng. 124 (2002) 528.
[9]. X. Cui and J. Zhao, Cutting performance of coated carbide tools in high-speed face milling of AISI H13 hardened steel, Int. J. Adv. Manuf. Technol., vol. 71, no. 9–12, pp. 1811–1824, (2014).
[10]. A. Gente, H.-W. Hoffmeister, and C. J. Evans, “Chip Formation in Machining Ti6Al4V at Extremely High Cutting Speeds,” CIRP Ann. - Manuf. Technol., vol. 50, no. 1, (2001) 49–52..
[11]. J. Hua and R. Shivpuri, “Prediction of chip morphology and segmentation during the machining of titanium alloys,” J. Mater. Process. Technol., vol. 150, no. 1–2, pp. 124–133, 2004.
[12]. Q. Yang, Y. Wu, D. Liu, L. Chen, D. Lou, Z. Zhai, and Z. Liu, “Characteristics of serrated chip formation in high-speed machining of metallic materials,” Int. J. Adv. Manuf. Technol., (2016). 1–6, Jan.
[13]. C. Duan, T. Tou and M. Wang, “Experimentalresearch of chip formation mechanism during high speed machining of hardened steel,” Int. J. Comput. Aided Eng. Technol., (2011) vol. 3, no. 5/6, p. 458.
[14]. A. Daymi, M. Boujelbene, S. Ben Salem, B. Hadj Sassi, S. Torbaty, and B. H. Sassi, “Effect of the cutting speed on the chip morphology and the cutting forces,” Int. Sci. J., (2009) vol. 1, no. 2, pp. 77-83.
[15]. Ş. Aykut, E. Bagci, A. Kentli, and O. Yazicioglu, “Experimental observation of tool wear, cutting forces and chip morphology in face milling of cobalt based super-alloy with physical vapour deposition coated and uncoated tool,” Mater. Des., (2007) vol. 28, no. 6, pp. 1880–1888.
[16]. M. Wang, B. Xu, J. Zhang, S. Dong, and S. Wei, “Experimental observations on surface roughness, chip morphology, and tool wear behavior in machining Fe-based amorphous alloy overlay for remanufacture,” Int. J. Adv. Manuf. Technol., (2013) vol. 67, no. 5–8, pp. 1537–1548, Jul.
[17]. G. G. Ye, S. F. Xue, W. M. Ma, Q. Jiang, Z. Ling, X. H. Tong, and L. H. Dai, “Cutting AISI 1045 steel at very high speeds,” Int. J. Mach. Tools Manuf., (2012) vol. 56, pp. 1–9.
[18]. Lê Công Đường, Vật liệu học, NXB Khoa học kỹ thuật. (1996).
[19]. Wang Z, Rahman M High-Speed Machining. In: Compr. Mater. Process. Elsevier, (1992) pp 637-643
[20]. I.King R Handbook of High Speed Machining Technology. (1985).
[21]. Nieminen I, Paro J, Kauppinen V High-speed milling of advanced materials, J Mater Process Technol, (1996) 136, 24-36.
[22]. Bành Tiến Long, Trần Thế Lực, Trần Sỹ Tùy Nguyễn lý gia công vật liệu. NXB Khoa học kỹ thuật, Hà Nội (2013).