New milling methodology for sealing planes in AlSi9Cu3(Fe) alloy machined with PCD tool

Abstract

The use of self-moulding resins in industry makes it necessary to specify minimum values for the surface roughness parameters in order to avoid fluid leaks between the sealing planes. To meet this requirement, new tool classes, machining parameters, and methodologies are being used. Thus, this work applies a new methodology for plane milling, with the objective of increasing the tightness of the union with adhesive. The investigation was based on experimental planning techniques for the behaviour of the surface roughness in machining of AlSi9Cu3 alloy by frontal milling with refrigeration, carried out in a transmission union support, in high-speed cutting (HSC) machining centres. The evaluated parameters were the cutting speed (Vc) between 1250 m/min and 2250 m/min, and the feed per tooth (fz) between 0.050 mm/tooth and 0.100 mm/tooth. Two cutters with ten polycrystalline diamond (PCD) inserts were used to mill the sealing surface, with one of the cutters having eight cutting inserts and two scratching inserts. The cutoff considered was 2.5 mm and the statistical technique of design of experiment (DOE) was used to evaluate the experimental results. The optimum roughness values, achieved with the cutter with scratching inserts, were a Vc of 1250 m/min and fz of 0.05 mm/tooth.