Abstract
In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.
Highlights
Machining lightweight materials is an important manufacturing process in the automobile and aerospace industries [1]
At a constant cutting speed of 70.6 m/min, the feed rate was varied in the range of 0.75–1.50 mm/s to realize the different feed ratios (FR), as listed in Table 1, for the variation of machining mechanics and, the chip formation characteristics in macro/conventional turning
Al alloy produced at different feed rates feed exhibited characteristics, Al alloymicrochips microchips produced at different ratesdifferent exhibited different as shown in the optical images chips produced at a feed rateatof characteristics, as shown in the optical images Figure 3
Summary
Machining lightweight materials (like Al alloy) is an important manufacturing process in the automobile and aerospace industries [1]. The micro machining of Al alloy is gaining importance due to the increased applications in precision micro industries [2]. Machining force, power consumption, surface finish, chip shape, and size are often used for the evaluation of machinability [6]. Properties such as low weight/strength ratio, good formability, high mechanical strength, improved fatigue performance, and fracture toughness have made aluminum alloys widely applicable in the aeronautic [7,8] and automotive industries [9]. Al 7050-T7451 is used for aircraft structure [13]
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