The main purpose of this work is to study the influence of copper content on Al-Si-Mg aluminum alloy's (6351) machinability. This alloy's machinability was evaluated through cutting tool torque and thrust force measurements, holes' surface roughness, diameter, roundness, cylindricity and subsurface modifications during the reaming process. The Al-Si-Mg alloy samples were produced with five levels of copper (0.07%, 0.23%, 0.94%, 1.43% and 1.93%) and have a chemical composition of the other alloying elements practically constant within the recommended range by the Aluminum Association for this alloy. The main mechanical properties of the 6351 aluminum alloy samples were obtained by microstructural analysis and microhardness, hardness and tensile tests. Major amounts of copper resulted in a significant increase in microhardness, hardness and ultimate tensile strength of the aluminum alloy, while elongation after fracture decreased. A 2 3 factorial design was used to verify the effect of copper content and cutting parameters cutting speed and feed rate in machinability responses. Furthermore, it was developed an adjusted model to optimize the cutting parameters selection to machine the alloy with the best copper content for each response parameter of the reaming process. The results showed a significant influence of copper content in this aluminum alloy's machinability. Lower values of torque and thrust forces, better surface finish, lower roundness and cylindricity deviation were obtained increasing copper content in Al-Si-Mg aluminum alloy (6351).
The main purpose of this work is to study the influence of copper content on Al-Si-Mg aluminum alloy (6351) machinability. The machinability was evaluated through cutting tool torque and thrust force measurements, machined surface roughness, roundness, cilindricity and burrs formation, chip form and sub superficial modifications during drilling, reaming and tapping processes. The 6351 aluminum alloy samples were produced with five levels of copper (0.07%, 0.23%, 0.94%, 1.43% and 1.93%) with chemical composition of the other alloying elements practically constant within the recommended range by The Aluminum Association for this alloy. The main mechanical properties of the 6351 aluminum alloy samples were obtained by microstructural analysis and microhardness, hardness, tensile and impact tests. Major amounts of copper resulted in significant increase in microhardness, hardness and ultimate tensile strength of the aluminum alloy, while elongation after fracture decreased. A 23 factorial design was used to verify the effect of copper content and the cutting parameters, cutting speed and feed rate, in the machinability responses. Furthermore, an adjusted statistical model was developed to optimize the cutting parameters selection of the best copper content for each response. The results showed significant influence of copper content in machinability. Lower values of torque and thrust forces, lower roundness and cilindricity, better surface finish, besides smaller chips and burrs were obtained increasing copper content in Al-Si-Mg aluminum alloy (6351).
RESUMO: O objetivo principal deste trabalho é avaliar os efeitos da velocidade de corte e da pressão de aplicação do fluido de corte no desempenho do processo de usinagem com base nos experimentos realizados no trabalho Taguchi's Technique in Machining of Metal Matrix Composites (SHETTY et al., 2008). O material da peça usinada foi um compósito de matriz metálica, constituído por uma matriz de liga de alumínio 6061 e partículas de carboneto de silício. O torneamento foi a operação de usinagem selecionada e a ferramenta de corte utilizada foi o nitreto cúbico de boro. O fluido de corte empregado foi o vapor d'água saturado. Para a realização do trabalho adotou-se a combinação dos parâmetros velocidade de corte e pressão de vapor variando em dois níveis, 45 e 101 m/min e 4 e 10 bar, respectivamente, na determinação dos tratamentos. A partir dessa combinação coletaram-se os dados obtidos por Shetty et al. para cada parâmetro de saída avaliado: desgaste da ferramenta de corte, força de corte, força de avanço e rugosidade. Esses dados foram submetidos à Análise de Variância e ao teste de Tukey a 5%. Os resultados dos efeitos de cada tratamento foram analisados para cada um dos parâmetros de saída concluindo que tanto a velocidade de corte como a pressão de aplicação do fluido de corte possui efeito sobre a usinabilidade do material. Palavras-chave: Usinagem. Velocidade de Corte. Pressão do fluido de corte. ANOVA. Usinabilidade.
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