Effect of Equal Channel Angular Pressing on the Surface Roughness of Solid State Recycled Aluminum Alloy 6061 Chips

Abstract

Solid state recycling through hot extrusion is a promising technique to recycle machining chips without remelting. Furthermore, equal channel angular pressing (ECAP) technique coupled with the extruded recycled billet is introduced to enhance the mechanical properties of recycled samples. In this paper, the surface roughness of solid state recycled aluminum alloy 6061 turning chips was investigated. Aluminum chips were cold compacted and hot extruded under an extrusion ratio (ER) of 5.2 at an extrusion temperature (ET) of 425°C. In order to improve the properties of the extruded samples, they were subjected to ECAP up to three passes at room temperature using an ECAP die with a channel die angle(Φ)of 90°. Surface roughness (RaandRz) of the processed recycled billets machined by turning was investigated. Box-Behnken experimental design was used to investigate the effect of three machining parameters (cutting speed, feed rate, and depth of cut) on the surface roughness of the machined specimens for four materials conditions, namely, extruded billet and postextrusion ECAP processed billets to one, two, and three passes. Quadratic models were developed to relate the machining parameters to surface roughness, and a multiobjective optimization scheme was conducted to maximize material removal rate while maintaining the roughness below a preset practical value.

Artificial Intelligence Monitoring of Hardening Methods and Cutting Conditions and Their Effects on Surface Roughness, Performance, and Finish Turning Costs of Solid-State Recycled Aluminum Alloy 6061 Сhips

“…Turning now to the papers that have described the establishment of optimum surface roughness in turning [40][41][42][43][44][45][46], Zuperl and Cus [40] proposed a neural network-based approach to complex optimization of cutting parameters, considering technological, economic, and organizational limitations. Gupta et al [41] focused on process parameter optimization in turning operations: surface roughness, flank tool wear, and required power using an ANN integrated with a genetic algorithm (GA).…”

“…Bataineh and Dalalah [44] proposed a strategy for optimizing the cutting parameters of dry turned aluminum alloys (6061-T6), to improve surface roughness and machining time and to minimize machining costs. Abbas et al [45] investigated surface roughness in the turning of solid-state recycled aluminum alloy 6061 chips. Ragab et al [46] investigated the effect of extrusion temperature and turning parameters on the surface roughness of aluminum alloys 6061.…”

“…Ragab et al [46] investigated the effect of extrusion temperature and turning parameters on the surface roughness of aluminum alloys 6061. However, studies [40][41][42][43][44][45] provided only a one-sided interpretation of the problem of estimating the optimum cutting conditions by taking surface roughness into consideration, but not its correlation with the unit volume machining time, T m , and the cost of machining, C, which is unacceptable in the machining of materials as expensive as an aluminum alloy 6061.…”

Solid-State Recycling of Light Metal Reinforced Inclusions by Equal Channel Angular Pressing: A Review

“…MMCs are promising materials for number of specific applications in aerospace, defence, and automobile industries [23]. The parameters such as ECAP routes, inner angle Ф, outer angle ѱ.…”

Development and FEM Modeling of a New Severe Plastic Deformation Process according to the Reverse Shear Scheme

“…For example, in the ECAE process, the deformation zone moves along the workpiece when it passes through a die with angular channel. In this case, dead zones are formed at the edges of the workpiece [11][12][13][14][15][16][17][18][19][20][21]. Similar deformation conditions are realized during Twist Extrusion (TE) [5].…”