Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts

Abstract

The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.

Investigation and Optimization of the SLM and WEDM Processes’ Parameters for the AlSi10Mg-Sintered Part

“…Just behind steel, aluminum and its alloys are the second most common material used in industries such as automotive, aerospace, machinery, manufacturing, transportation, and construction. Wide application of these materials is determined by their specific properties such as light weight, resistance to corrosion, and great mechanical properties including excellent strength and stiffness [ 1 , 2 , 3 ]. One of the most commonly used aluminum alloys is AlSi10Mg, which belongs to the group of hypoeutectic aluminum alloys [ 4 ].…”

In-Situ Synthesis, Microstructure, and Mechanical Properties of TiB2-Reinforced Fe-Cr-Mn-Al Steel Matrix Composites Prepared by Spark Plasma Sintering

“…It is well known that Metal Matrix Composites (MMCs) are being used increasingly in the automotive industry [ 3 ], cutting tools [ 4 , 5 , 6 ], and aerospace [ 7 ], due to their strength, quality, and light weight. Ceramic particle reinforced metal matrix composites are composed of ductile metal matrix and ceramic particle reinforced matrix, which have good plastic toughness and high strength stiffness.…”