Abstract
The present work has been focused on cutting force (Fc) and analysis of machined surface in turning of AA 6061 alloy with uncoated and PVD-TiB2 coated cutting inserts. Turning tests have been conducted on a CNC turning under dry cutting conditions based on Taguchi L18 (21 × 33) array. Kistler 9257A type dynamometer and equipment have been used in measuring the main cutting force (Fc) in turning experiments. Analysis of variance (ANOVA) has been applied to define the effect levels of the turning parameters on Fc and Ra. Moreover, the mathematical models for Fc and Ra have been developed via linear and quadratic regression models. The results indicated that the best performance in terms of Fc and Ra was obtained at an uncoated insert, cutting speed of 350 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1 mm. Moreover, the feed rate is the most influential parameter on Ra and Fc, with 64.28% and 54.9%, respectively. The developed mathematical models for cutting force (Fc) and surface roughness (Ra) present reliable results with coefficients of determination (R2) of 96.04% and 92.15%, respectively.
Highlights
In our world, where global warming has been felt quite a lot in recent years, the need for intelligent methods and light materials is increasing
CO2 emission is an important criterion in terms of environmental pollution. e gaseous wastes of the environment are largely dependent on the CO2 emissions produced by the transport industry [1]. e use of lightweight materials for many automotive components is increasing in the automotive industry, where CO2 emissions are considered
Surface Roughness and Cutting Force Measurement. e surface roughness of the test samples was measured using the Mahr Perthometer M1 model test device. e cutoff length was 0.8 mm and the measurement length was 12 mm. e surface roughness values were determined from measurements taken at three different points on the machined surfaces formed after each experiment. en, the average surface roughness (Ra) was determined by calculating the average of the measurements
Summary
In our world, where global warming has been felt quite a lot in recent years, the need for intelligent methods and light materials is increasing. CO2 emission is an important criterion in terms of environmental pollution. E gaseous wastes of the environment are largely dependent on the CO2 emissions produced by the transport industry [1]. E use of lightweight materials for many automotive components is increasing in the automotive industry, where CO2 emissions are considered. Fuel savings are achieved by reducing weight by using light materials. An example of lightweight materials is the AA 6061 alloy. E main alloying element of this material is magnesium and silicon. The density of this alloy of 2.63 g/cm makes it important for applications where the strength-to-weight ratio is considered in the automotive, aircraft, and aerospace industries. AA 6061 alloy is preferred more than other aluminium series because of their properties such as strength, formability, weldability, corrosion resistance, and low cost [2]
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