Abstract
The present study was conducted on the machinability of 396 alloy (containing approximately 11% Si) and B319.2 alloy mainly to emphasize the effects of Fe-intermetallics, i.e., α-Fe, β-Fe, and sludge. The results demonstrate that the presence of sludge in the form of hard spots has a significant effect on cutting forces and tool life, in that it decreases drill life by 50% compared to the base alloy. The formation of the α-Fe phase in the M1 base alloy has a beneficial effect on tool life in that this alloy produces the highest number of holes drilled compared to alloys containing sludge or β-Fe; this result may be explained by the fact that the formation of the α-Fe intermetallic, with its rounded Chinese script morphology and its presence within α-Al dendrites, is expected to improve matrix homogeneity via hardening of the soft α-Al dendrites. Increasing the Fe-content from 0.5% to 1% in the 396-T6 alloy containing 0.5% Mn produces a distinct improvement in alloy machinability in terms of cutting force and tool life. The addition of Fe and/or Mn appears to have no discernible effect on the build-up edge area (BUE) and chip shape.
Highlights
The 319 and 396 cast aluminum alloys are typically used for the production of aircraft pump parts, automotive transmission cases, aircraft fittings and controls, water-cooled cylinder blocks, and numerous other applications
One of the approaches suitable for improving machinability is the use of free-cutting elements to improve the machinability of any given material because they provide a smooth surface, cause less tool wear, and produce chips which are more breakable [12]: It should be mentioned here that the pertinent machinability criteria relate to force and moment as well as to tool life, chip configuration, and build-up edge (BUE) evolution
Eight alloys were prepared using the 396 alloy, they were classified into three groups according to the additives used, namely, Fe-intermetallic elements, matrix-hardening elements, and free cutting elements
Summary
The 319 and 396 cast aluminum alloys are typically used for the production of aircraft pump parts, automotive transmission cases, aircraft fittings and controls, water-cooled cylinder blocks, and numerous other applications. One of the approaches suitable for improving machinability is the use of free-cutting elements to improve the machinability of any given material because they provide a smooth surface, cause less tool wear, and produce chips which are more breakable [12]: It should be mentioned here that the pertinent machinability criteria relate to force and moment as well as to tool life, chip configuration, and build-up edge (BUE) evolution. In keeping with these aims, the objectives of this study will cover the following: 1.
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