Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review

Sarıkaya, Murat; Gupta, Munish Kumar; Tomaz, Ítalo; Danish, Mohd; Mia, Mozammel; Rubaiee, Saeed; Jamil, Muhammad; Pimenov, Danil Yurievich; Khanna, Navneet

doi:10.1016/j.jmapro.2020.12.013

Cited by 117 publications

(32 citation statements)

References 182 publications

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“…The microstructure of the cutting tool was previously reported to influence the machined part's surface finish and cutting forces when machining Al6061 alloy [9]. Coolants can be an excellent choice to improve part finish when machining light alloys and to prolong tool life [10,11], but this is not always possible, depending on the final part requirements. The choice of feed rates and cutting speeds depends on the workpiece's mechanical properties, the material of the cutting tool, and its coating.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Al-Tameemi

Al-Dulaimi

Awe³

et al. 2021

Materials

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Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

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Section: Introductionmentioning

confidence: 99%

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Al-Tameemi

Al-Dulaimi

Awe³

et al. 2021

Materials

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“…Tool wear, chip formation, and hole quality are key parameters of the drilling process and are strongly influenced by spindle speed (n), feed rate (f ), tool geometry, machine tool setup, and cutting conditions such as wet/dry or other environmental factors [8][9][10][11][12]. In contrast to wet machining, dry drilling is preferable to reduce the environmental impact of coolants and eliminate the costs of cutting fluids [13]. However, during the dry drilling process, there are more chances of forming a built-up edge (BUE), which can reduce the tool's life and affect the hole quality [14].…”

Section: Introductionmentioning

confidence: 99%

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Aamir

Giasin

Tolouei‐Rad

et al. 2021

Metals

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Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

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“…Uncoated high-speed steel (HSS) twist drills (Dormer Drills, UK) with a helix angle of 30 • and a point angle of 130 • were used. All the drilling experiments were conducted under dry conditions due to environmental concerns [18]. Dry drilling also reduces the need to clean the aeronautical structures before installing rivets to obtain high-quality holes [19].…”

Section: Methodsmentioning

confidence: 99%

Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Habib

Sharif

Hussain

et al. 2021

Metals

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Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of drilling parameters such as spindle speed and feed rate on the chips analysis and the hole quality like surface roughness, hole size, circularity, and burr formation. Al7075-T6 alloy, commonly used in the aerospace industry, was used for the drilling process, and the dry drilling experiments were performed using high-speed steel drill bits. Results have shown that surface roughness decreased with the increase in spindle speed and increased with the increase in the feed rate. The hole size increased with the high spindle speed, whereas the impact of spindle speed on circularity error was found insignificant. Furthermore, short and segmented chips were achieved at a high feed rate and low spindle speed. The percentage contribution of each input parameter on the output drilling parameters was evaluated using analysis of variance (ANOVA).

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Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review

Cited by 117 publications

References 182 publications

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

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