Experimental studies on the cryogenic machining of biodegradable ZK60 Mg alloy using micro-textured tools

Abstract

ABSTRACTReducing the contact area between the cutting tool rake surface and chip promotes the machining performance of the work material and increases the tool life. Magnesium alloys are ductile-lightweight materials that form continuous chips during machining. The present investigation discusses the orthogonal turning of ZK60 magnesium alloy with linearly textured cutting inserts under both dry and liquid nitrogen (LN2) cooling conditions. Linear grooves that are parallel and perpendicular to chip flow direction were created using Nd-YAG laser on the tungsten carbide cutting inserts. The effect of texturing combined with the application of LN2 cooling is studied by evaluating the machining temperature and forces, microhardness, surface roughness and tool wear. Textured tools considerably minimize the liaison area of the chip with the rake plane compared to non-textured tools, which resulted in favorable effects in machinability. In case of cryogenic machining, textured tools substantially minimize the friction by the coupled effect of micro-pool lubrication and the formation of thin-film lubrication between the tool–chip/tool–work interfaces. Parallel-textured tools aided with cryogenic cooling exhibit superior performance during machining among the different types of tools employed in the present investigation.