Abstract
The influence of some turning variables and tool overhang on surface roughness parameters and residual stress induced due to machining 6061-T6 aluminum alloy is investigated in this paper. Four input parameters (cutting speed, feed rate, depth of cut and tool overhang) are considered. Tests are carried out by precision turning operation on a lathe. Design of experiment techniques, i.e. response surface methodology (RSM) and Taguchi's technique have been used to accomplish the objective of the experimental study. Surface roughness parameters are measured using a portable surface roughness device while residual stresses are measured employing deflection-etching technique using electrochemical analysis. The results obtained reveal that feed and rotational speed play significant role in determining the average surface roughness. Furthermore, the depth of cut and tool overhang are less significant parameters, whereas tool overhang interacts with feed rate. The best result of surface roughness was obtained using low or medium values of overhang with low speed and /or feed rate. Minimum maximum tensile residual stress can be obtained with a combination of tool overhang of 37 mm with very low depth of cut, low rotational speed and feed rate of 0.188 mm/rev.
Highlights
Aluminum alloys have high demand in many engineering applications because of their excellent mechanical properties
The surface topography comprises of surface roughness, waviness, form errors, and flaws whereas the subsurface layer characteristics that can change due to processing include plastic deformation, residual stresses, cracks, hardness, phase changes, re-crystallization and intergranular attack [1,2,3]
The main objective of the this work is to study the effects of tool overhang in addition to some turning parameters such as speed, feed rate and depth of cut on some surface integrity phases, namely surface roughness parameters and residual stress
Summary
Aluminum alloys have high demand in many engineering applications because of their excellent mechanical properties. In [6], authors studied the effect of turning the aluminum with tools having different cutting edge materials and tool edges shapes on the surface roughness. Another research which was conducted on two types of steel which have been machined by turning reported that residual stresses are influenced, to a great extent, by feed rate and nose radius and, to a certain extent, by the cutting speed and the rake angle. The effect of high cutting speeds and feed rate on residual stresses on different hard steel materials has been investigated [19,20,21]. The main objective of the this work is to study the effects of tool overhang in addition to some turning parameters such as speed, feed rate and depth of cut on some surface integrity phases, namely surface roughness parameters and residual stress. The RSM approach is applied to deduce mathematical models that relate the different input parameters to each response studied in this work
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