Abstract
Facing machinability tests were performed on the magnesium alloy castings AZ91 by measuring cutting resistance, shear angle, surface roughness and chip forming. Face cutting done from periphery to center of specimen with cemented carbide alloy K20 in which has various side rake angle. Regardless of the different side rake angles, both cutting forces and machined surface of the alloy were independent of cutting speed. The cutting resistances increased with increasing both feed rate and depth of cut, and decreased with increasing of side rake angle. The feed rate influenced a little to the machined surface, and it was superior to that of theoretical valves on the basis of feed marks and tool configuration. The orderly feed marks were observed on the machined surface, however, in the case of both high feed and large side rake angle, the burr and tear were observed on the machined surface. The size of the chips decreased with decreasing cutting speed and increasing feed rate. The thickness of the chips at start of cutting became thinner than that at end. The cutting ratio showed large value at the outer part of specimen under high cutting speed. The shear angle decreased with decreasing cutting speed. The AZ91 magnesium alloy castings had excellent facing machinability in high speed heavy cutting. The facing machinability of AZ91 magnesium alloy castings was excellent and exhibited good performance in high speed heavy cutting.
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