Experimental study of the influence of the process parameters in the milling of Al6082-T6 alloy

Jebaraj, M.; Kumar, M. Pradeep; Yuvaraj, N.; Rahman, G. Mujibar

doi:10.1080/10426914.2019.1594271

Cited by 37 publications

(8 citation statements)

References 55 publications

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“…Many of the previous research works have shown that cutting process parameters have a significant effect on surface roughness [ 27 , 34 , 42 ]. The feed per tooth has a significant effect on the cutting process [ 38 ] and on surface roughness [ 27 , 34 , 36 , 42 , 46 ]; however, the cutting speed and depth of cut also significantly affect the surface quality, as shown in the works [ 36 , 42 , 52 ]. To limit the effect of cutting parameters on the results of analyses of the effects of face milling strategies on the surface roughness, one set of cutting process parameters was used in the experimental study.…”

Section: Methodsmentioning

confidence: 99%

“…The quality of the machined surface may also depend on the wear level of the cutting edge [32,33]. Cutting edge wear during the cutting process and general cutting process can be assessed by monitoring cutting forces [34], whereas the monitored cutting forces can be used to predict the quality of the machined surface [35]. A lot of research works have been devoted to the analysis and optimisation of cutting process parameters to achieve low surface roughness levels [36][37][38], high dimensional accuracy [39], high process efficiency [40,41] and reduced energy consumption during the machining process [42].…”

Section: Introductionmentioning

confidence: 99%

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Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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“…In this study, the responses were considered as of equal weight-age. The steps given below are required for optimization in the TOPSIS method [22,23].…”

Section: Optimization Procedures Involved In the Topsis Methodsmentioning

confidence: 99%

Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Selvam

Murugesan

Dhananchezian³

et al. 2019

Metals

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Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (V c ) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique. on the workpiece materials and cutting conditions [2]. Various coated cutting tools (e.g., TiN, TiAlN, AlTiN, CrN) are available on the market, but machining of Ti alloy still sees problems like the formation of built-up edges on the tools, a rise in wear marks on the cutting edges, and poor quality of machined surfaces. Hence, it is vital to assess the machinability characteristics of Ti alloys in the turning operation using appropriate coatings on cutting tools and advanced techniques of cryogenic lubrication.Chauhan and Rawal [3] reported on nitride ion-based coatings, such as TiAlN, TiMoN, and TiVN, with different deposition techniques. They implied ternary nitride-based coatings showing a higher improvement in tribological and mechanical properties compared to the binary nitride coatings. Bouzakis et al. [4] discussed the evolution of cutting tool coating elements, related coating deposition techniques, manufacturing methods, recent characterization methods, film dimensional thickness, and recondition of wear on coated cutting tools. Their paper shows that as productivity increases, so does the need for improvement. Biksa et al. [5] analyzed the self-adaptive functional coating on cutting tools while machining nickel and titanium-based alloys. It showed the attainment of a better life for AlTiN/MoN-coated tools when machining Inconel 781 and AlTiN/VN-coated tools for Ti-Al6-V4 alloy. This coating was seen as having a smaller coefficient of friction at specific elevated temperatures. Nordegren et al. [6] investigated the plastic deformation modeling on layered carbide tool edges when machining AISI 4340 steel. The result indicated a determined finite element model for the edge thermal effect of the machining process.Ghani et al....

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“…Generally, the average flank wear (V b ) is utilized to quantify tool life. The tool rejection criteria were fixed (average flank wear 300 µm), and ISO 8688-2 [40] was followed. As illustrated in Fig.…”

Section: Progression Of Tool Wearmentioning

confidence: 99%

Effects of High-Pressure Coolant Jets on the Machinability of Ti-6Al-4V Alloy with External Rotary Liquid Applicator

Sultana

Dhar

2022

Preprint

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A novel rotary applicator has been designed to feed high-pressure coolant jets while maintaining the tool's strength in order to improve the Ti-6Al-4V alloy's poor machinability. Average cutting temperature, principal cutting force, mean surface roughness, and tool wear were all taken into account when evaluating the machinability of various speed-feed combinations. Dry milling produced the worst results for all of the investigated reactions, with excessive tool wear and poor machinability happening due to the lack of cooling and lubrication. HPC and RHPC both outperformed dry, but RHPC was the clear winner in all investigations. HPC is distinguished by the rotational supply of high pressurized coolant jets delivered through several nozzles rather than the typical nozzle. This results in effective cooling and lubricating during RHPC. The higher forced convection heat transfer mechanism of high-pressure cutting fluids controls cutting temperatures amazing along with its protective film formation. Cutting forces and surface roughness are reduced roughly 14% and 17.44% in RHPC compared to HPC. Similarly, as a result of better temperature management by RHPC, flank wear is greatly reduced while tool life is increased ( 9 min).

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Experimental study of the influence of the process parameters in the milling of Al6082-T6 alloy

Cited by 37 publications

References 55 publications

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Effects of High-Pressure Coolant Jets on the Machinability of Ti-6Al-4V Alloy with External Rotary Liquid Applicator

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