Abstract
The effects of different tool edge geometries (hone and chamfer (T-land)) on quantitative measurement of end (exit) burr and chip segmentation (frequency and degree) in machining of AA2024-T351 are presented in this work. The finite element (FE) approach is adopted to perform cutting simulations for various combinations of cutting speed, feed, and tool edge geometries. Results show an increasing trend in degree of chip segmentation and end burr as hone edge tool radius or chamfer tool geometry macro parameters concerning chamfer length and chamfer angle increase. Conversely, the least effects for chip segmentation frequency have been figured out. Statistical optimization techniques, such as response surface methodology, Taguchi’s design of experiment, and analysis of variance (ANOVA), are applied to present predictive models, figure out optimum cutting parameters, and their significance and relative contributions to results of end burr and chip segmentation. Various numerical findings are successfully compared with experimental data. The ultimate goal is to help optimize tool edge design and select optimum cutting parameters for improved productivity.
Highlights
Aluminum alloys are widely used in the aerospace industry due to their excellent strength-to-weight ratios and thermal properties
Certain complex combinations of tool materials, tool cutting angles, tool edge geometry, chip breaker profiles, cutting process parameters, machine dynamics, among others, greatly influence high-speed cutting processes and may result in high cutting temperatures and intense localized deformations, as reported in numerous experimental and numerical studies performed on aluminum alloys, such as AA2024-T351, AA7010-T7451, and AA7050-T7451
This paper provides more comprehensive information on burr formation (“negative burrs” at the exit end of workpiece), crack propagation at the front of the tool edge, formation of negative shear zones and pivot point locations, boot-type chip formation, and associated burr generation phenomena
Summary
Aluminum alloys are widely used in the aerospace industry due to their excellent strength-to-weight ratios and thermal properties. Higher values for the tool edge chamfer length (lβ ), chamfer angle (γβ ), and hone edge radius (rβ ) will certainly increase the negative rake angle in the vicinity of the stagnation point, and the increased workpiece area will experience high thermo-mechanical load This will largely influence the primary shear zone, negative shear zone (responsible for exit burr formation), and material degradation, in turn reducing the augmentation of chip segmentation and leading to longer burr lengths. The eventual aim of the presented work is to provide further insight into chip and burr formation in machining of AA2024-T351 and to optimize cutting parameters and tool edge design for improved productivity, employing a finite element (FE)-based design and analysis approach.
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