Characterizing the Effect of 319 Aluminum Microstructure on Machinability: Part 1 — Model Development

Abstract

This two-part paper is directed at the development of a machining force model that addresses key microstructural features of 319 Aluminum. In Part 1 of this paper, a machining force model is presented that incorporates microstructural effects. Secondary Dendrite Arm Spacing (SDAS) is identified as a significant microstructure feature of 319 aluminum in terms of machinability, and the SDAS is related to the solidification rate. A new material constitutive relationship that incorporates SDAS microstructure effects is proposed. In Part 2 of this paper, the results from material tests and machining experiments are presented. A new methodology for estimating parameters within the material constitutive model is described, and force model predictions are compared with the results from machining tests. The comparison reveals an excellent agreement between measured and predicted forces.