Abstract
In this article, the influence of electropulsing on the machinability of steel S235 and aluminium 6060 has been studied during conventional and electropulsing-assisted turning processes. The machinability indices such as chip compression ratio , shear plane angle and specific cutting energy (SCE) are investigated by using different cutting parameters such as cutting speed, cutting feed and depth of cut during electrically-assisted turning process. The results and analysis of this work indicated that the electrically-assisted turning process improves the machinability of steel S235, whereas the machinability of aluminium 6060 gets worse. Finally, due to electropluses (EPs), the chip compression ratio increases with the increase in cutting speed during turning of aluminium 6060 and the SCE decreases during turning of steel S235.
Highlights
Studying the behaviour of metallic alloys during machining is very important in the manufacturing industry
Commercial steel alloys (S235) and aluminium alloys (Al 6060) of 20 mm diameter were chosen as workpiece materials for test specimens
The current density which is defined as current intensity through the cross sectional area of the material during cutting, can be considered as an important factor in changing the deformation resistance of material in primary shear zone
Summary
Studying the behaviour of metallic alloys during machining is very important in the manufacturing industry. The high process efficiency can be achieved by minimizing the energy required to remove the material as plastically deformed chip [2]. An increase in cutting speed tends to decrease of chip thickness and the region of plastic deformation becomes smaller which reduces the energy consumption [4]. It was generally observed that in metal cutting processes only 30–50% of energy is spent for useful work, while 25–60% of energy consumed during cutting is wasted [5]. Reducing the energy spent in metal cutting as much as possible by selecting properly the workpiece material, machining regime and process parameters is of great importance. The energy consumption in metal cutting processes is a function of cutting speed, feed rates and workpiece material [6].
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