Dry machining of aluminum for proper selection of cutting tool: tool performance and tool wear

Pattnaik, Sisira Kanta; Bhoi, Neeraj Kumar; Padhi, Sachidananda; Sarangi, Saroj Kumar

doi:10.1007/s00170-017-0307-0

Cited by 49 publications

(25 citation statements)

References 39 publications

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“…The material strengthening in case of the Al-2ZnO can be beautifully explained by Orowan strengthening mechanism. The Orowan strengthening is stated in equation (8) Orowan ¼ 0:13Gb ln r b ð8Þ…”

Section: Densification Behavior Of the Developed Composite Materialsmentioning

confidence: 99%

“…1,2 Ceramic reinforcements like Al 2 O 3 , SiC, BN, TiB 2 , TiC, VC, Si 3 N 4 , Y 2 O 3 , and similar elements are widely engaged for the enhancement in the strength and modulus of aluminum (Al) since the ceramics are harder and have superior thermal stability. [3][4][5][6][7][8][9] The utilization of whiskers in the form of a different oneand two-dimensional structure enhances the material properties significantly. The whiskers hold good thermal, chemical, structural, and tribological stability over other particles when they are used for reinforcement in the metal matrix.…”

Section: Introductionmentioning

confidence: 99%

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Synthesis and characterization of zinc oxide reinforced aluminum metal matrix composite produced by microwave sintering

Bhoi

Singh

Pratap

2020

Journal of Composite Materials

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The study focuses on the microstructural, phase transformation, and physical and mechanical aspects of aluminum/zinc oxide composite produced by a hybrid microwave sintering technique. In the present case, zinc oxide nanorods were synthesized through a cost-effective thermal decomposition method. The obtained zinc oxide nanorods’ length was in the range of 76–168 nm observed through high-resolution transmission electron microscopy images and crystallinity nature was confirmed by the bright spot in the selected area electron diffraction pattern. Two different wt% (i.e. 0.5 and 2) of zinc oxide nanorods were utilized for the fabrication of the composite material. The diffraction pattern of the milled powder and energy dispersive spectroscopy results shows effective diffusion of zinc oxide nanorods in the aluminum. The elemental mapping of milled powder illustrates the uniform distribution of the reinforcement over matrix material. The micro-hardness results exhibit a higher hardness of 27.78% with a small fraction of 2 wt%. The nano-indentation results confirm the improvement in the nano-hardness by 32.21% with 2 wt% of zinc oxide with a marginal decrease in elastic modulus by 4.92%.

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Section: Densification Behavior Of the Developed Composite Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Synthesis and characterization of zinc oxide reinforced aluminum metal matrix composite produced by microwave sintering

Bhoi

Singh

Pratap

2020

Journal of Composite Materials

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“…They found that the PCD tool has superior performance than the WC tool, which was very much expected. Pattnaik et al [23] previously reported their work on dry machining of aluminium. They used five different advanced cutting tools (WC SPUN andSPGN; TiC and multicoated WC; PCD).…”

Section: Literature Reviewmentioning

confidence: 99%

Influence of cutting parameters on cutting forces and surface roughness in dry turning of Al using PCD and different coated tools

et al. 2019

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Aluminium (Al) is the suitable material for aerospace and automotive industries due its light weight, corrosion resistance, weldability, non-magnetic and mechanical properties. But, machining of Al and its alloy and finding the suitable tool is really a big challenge because of its formation of BUE (Built-up Edge) and BUL (Built-up Layer). This paper presents the influence of cutting parameters (speed, feed and depth of cut) and its effect on the cutting force and the surface finish. Five different advanced cutting tool inserts (SPUN WC, SPGN WC, PCD, WC ? TiN and WC ? Ti(C, N) TiN ? Al 2 O 3 ) at different cutting speed (V c ) ranging between 300 m/min and 700 m/min and feed rate (f) of 0.045, 0.06, 0.09 and 0.125 mm/rev at a depth of cut of 0.2 mm (constant throughout the experiment) were taken for the experiment. Tool inserts were characterized by Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analysis. The cutting forces were measured using Kistler force dynamometer. Amongst all tools, PCD provided a better result in all aspects but surprisingly WC tool provided a better surface finish with lesser tool wear. For all cutting conditions, high speed (670 m/min) and low feed rate (0.045 mm/rev) were recommended. adhana(0123456789().,-volV)FT3 ](0123456789().,-volV)

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“…Further, the dry cool environment is found to provide better results for chip formation (Eapen et al [10]). However, the PCD tool has been proved to give better results pertaining to tool wear, chips and surface roughness (Pattnaik et al [11]). Further, the application of high-frequency vibration to rotary tool, tend to reduce the cutting force and surface roughness while turning of A7075 (Teimouri et al [12]).…”

Section: Introductionmentioning

confidence: 99%

Cutting Performance Analysis of Surface Textured Tools in Dry Turning: Optimisation of process parameters

Roy

Dash²,

Mahapatra

et al. 2021

E3S Web Conf.

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Owing to minimum quantity or no use of toxic coolants, the dry machining technique has been evidenced to be a versatile sustainable method. However, during dry machining of ductile alloys, the severe tool wear and metal adhesion on the rake face of the cutting tool has been a matter of great concern. In the present work, an attempt has been made to assess the improvement in the tribological conditions in dry cutting by providing surface texturing on the rake face of High-Speed Steel (HSS) cutting tool. Dimples were produced on the rake surface of the HSS tool using pulsed Nd: YAG Laser and dry turning of pure aluminium is performed using the textured tool based on Taguchi’s L9 orthogonal array (OA) experimental design. The dry cutting of pure aluminium was also performed using the conventional/un-textured tool and the obtained results are used for comparison purpose. Improved turning performance in terms of material removal rate and surface roughness is found from the conformation tests using optimum process parameter determined by the Taguchi analysis. The ANOVA results suggests the effectiveness of using the textured tools during dry machining is significantly affected by feed and speed.

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Dry machining of aluminum for proper selection of cutting tool: tool performance and tool wear

Cited by 49 publications

References 39 publications

Synthesis and characterization of zinc oxide reinforced aluminum metal matrix composite produced by microwave sintering

Synthesis and characterization of zinc oxide reinforced aluminum metal matrix composite produced by microwave sintering

Influence of cutting parameters on cutting forces and surface roughness in dry turning of Al using PCD and different coated tools

Cutting Performance Analysis of Surface Textured Tools in Dry Turning: Optimisation of process parameters

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