Effect of Coating and Polishing of Cutting Tool on Machined Surface Quality in Dry Machining of Aluminium Alloy
Abstract
Surface quality is one of the major concerns in any machining process. To achieve the higher surface finish, mostly concentrated on machining parameter optimisation. This study has been carried out to study the effect of coating and polishing of flute surface of the solid carbide (WC-Co) endmill cutters on machined surface quality obtained during dry machining of Aluminium alloy 24345WP. Experiments were conducted on Aluminum workpieces with Ø6 mm 2 flute end- mill cutter with and without coating/polishing and their effect on surface quality studied for linear as well as areal surface roughness parameters using white light interferometery. The study concludes that polished flute tool, despite their non-sharp cutting edges, gives considerably better surface finish due to its lowering of chip tool friction. This was also supported by the results obtained from scanning electron microscopy of the cutting tool edge as well as optical microscopy of the obtained machined surface.
References
Hiromi, Yoshimura; Yoshikazu, Toda; Moriwaki, Shibasaka; Toshimichi, Toshiro & Junya, Okida. Study on near dry cutting of aluminum alloys. Mach. Sci. Technol.: Int. J., 2006, 10:3, 289-299. https://doi.org/10.1080/10910340600902108
Nouari, M.; List, G.; Girot, F. & Coupard, D. Experimental analysis and optimisation of tool wear in dry machining of aluminium alloys. Wear, 2003 255, 1359–1368. https://doi.org/10.1016/S0043-1648(03)00105-4
Carrilero, M.S.; Sola, J.M.S.; Sanchez, J.M.; Alvarez, M.; Gonzalez, A. & Marcos, J.M. A SEM and EDS insight into the BULand BUE differences in the turning process of AA2024 Al–Cu Alloy. Int. J. Mach. Tools Manuf., 2002, 42, 215–220. https://doi.org/10.1016/S0890-6955(01)00112-2
Fukui, H.; Junya, Okida; Naoya, Omori; Hideki Moriguchi, Keiichi Tsuda. Cutting performance of DLC coated tools in dry machining aluminum alloys. Surface Coatings Technol., 2004, 187, 70–76. https://doi.org/10.1016/j.surfcoat.2004.01.014
Kanchana, J.; Prabhuraja, V.; Prakash, R. and Radhakrishnan, P. Dynamics of high-speed machining of aerospace structures using finite- element analysis. Def. Sci. J., 2002, 52(4), 403-408. https://doi.org/10.14429/dsj.52.2197
Bobzin, K. High-performance coatings for cutting tools. CIRP J. Manuf. Sci. Technol., 2016, 405, 1755-5817. https://doi.org/10.1016/j.cirpj.2016.11.004
Richter A. Flute polishing boosts surface integrity. Cutting Tool Engineering, 2013. https://www.ctemag.com/news/articles/flute-polishing-boosts-surface-integrity (Accessed on 03 January 2019).
Jie, Gu; Gary, Barber; Simon, Tung & Ren-Jyh, Guh. Tool life and wear mechanism of uncoated and coated milling inserts. Wear, 1999, 225(1), 273-284. https://doi.org/10.1016/S0043-1648(99)00074-5
Chattopadhyay, A.K.; Roy, P. Ghosh & Sarangi, S.K. Wettability and machinability study of pure aluminium towards uncoated and coated carbide cutting tool inserts. Surface Coating Technol., 2009, 203(8), 941–951. https://doi.org/10.1016/j.surfcoat.2008.08.047
Bhowmick, S.; Banerji, A. & Alpas, A.T. Tribological behavior of Al- 6.5%, - 12%, - 18.5% Si alloys during machining using CVD diamond and DLC coated tools. Surface Coatings Technol., 2015, 284, 353–364. https://doi.org/10.1016/j.surfcoat.2015.08.073
Das, D.K.; Mishra, P.C.; Sahoo, A.K. & Ghosh, D. Experimental investigation on cutting tool performance during turning AA 6063 using uncoated and multilayer-coated carbide inserts. Int. J. Mach. Mach. Mater., 2015, 17(3/4), 277–294. https://doi.org/10.1504/IJMMM.2015.071996
where otherwise noted, the Articles on this site are licensed under Creative Commons License: CC Attribution-Noncommercial-No Derivative Works 2.5 India