Abstract
The effects of the tool dimensions, specimen diameter and the depth of cut on the chip formation characteristics of 2011 (T3) aluminum alloy have been investigated. It has been shown that the chip-treatability can be successfully interpreted in terms of the number of chips, N, produced when a constant amount of materials (100 g in the present work) is cut. At a high cutting speed, N decreases steeply and then increases again with increasing feed. It has been observed that continuous type chips are produced in the specific range of feed, termed the critical feed, at a certain higher cutting speed. Thus plotting N as a function of feed, there appears a discontinuity.It has been shown that N increases with increasing back rake angle and more markedly with decreasing side rake angle, showing a strong dependence of the free-machining property on the tool dimensions. The effects of the back rake angle and the side rake angle on the machinability are particularly strong when the feed is near the critical value. The specimen diameter and the depth of cut have been shown to have little effect on the free-machining characteristics.
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