Abstract
The general machining characteristics of aluminium pressure die cast and die cast alloys under various machining conditions for turning, face milling and drilling are listed and discussed. Workpiece-tool interaction, when machining aluminium cast alloys results in an abrasive flank wear, influences the shape and the dimensional accuracy as well as the surface integrity of the workpiece. Main factors of the investigations were tool wear, cutting forces and surface roughness. The influence of silicon content, porosity and multiple cut interruption on the tool life was studied. Recommendations are made for maintenance of tool life and avoidance of built-up edges or adhesive welded particles. Cast surface quality and influence of other work material defects are considered and illustrated. Cracking of the free silicon in the workpiece can occur, when machining aluminium cast alloys. For machining aluminium cast alloys with high silicon content a limit for the applicable cutting speed was found: the point of thermal overloading of the work material in the shear zone by means of a deceptive chip formation.
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