Observation of Built-up Edge Formation on a Carbide Cutting Tool with Machining Aluminium Alloy under Dry and Wet Conditions

U.A.A Azlan,M Hadzley,N.Z Noriman,A.A Azhar,N Fauzi Tamin,F.M Noor,M Rahimi Yusoff,M.A.B Abdullah,M.E Muhammad Suandi,S.Z Abd Rahim,M.N Mat Saad,M.F Ghazali

doi:10.1051/matecconf/20179701076

Abstract

This paper presents the morphology of built-up edge (BUE) formation under wet and dry conditions with low and high cutting speeds. The workpiece materials and cutting tools selected for this work were aluminium alloy and canela carbide inserts graded PM25. The cutting tools underwent turning operation machining tests and their performance was evaluated by the flank wear and observation of the tool wear area. The machining tests were conducted at different spindle speeds and feed rates while the cut depth was kept constant. The analysis showed that formation of the BUE was dominant at low cutting speeds in dry conditions, but in wet conditions at high cutting speeds, a better performance was exhibited in terms of wear analysis.

Highlights

Aluminium alloy is a lightweight material that has been widely used in manufacturing industries, especially in the automotive and aeronautics sectors
The graph shows that low flank wear was recorded at a starting point of 10,000 m/min, increased tremendously at 15,000 m/min, gradually decreased at 22,000 m/min and slightly increased at the end of 71,000 m/min
It clearly shows that the flank wear in wet cutting was lower than in dry cutting for most of the cutting conditions, except at the higher cutting speed of 71,000 m/min

Summary

Introduction

Aluminium alloy is a lightweight material that has been widely used in manufacturing industries, especially in the automotive and aeronautics sectors. This is because of its superior mechanical behaviour; exhibiting good corrosion resistance, low density, high strength and low-cost material [1]. Despite the advantages of this aluminium, there are some difficulties machining this material especially when the cutting parameter is not applied correctly. Apart from obtaining accurate dimensions, achieving a good surface quality and maximizing metal removal are important criteria. Machining aluminium is normally applied in dry conditions whereby the processes are normally applied to finishing and cleaning environments. Machining aluminium sometimes produces quick tool wear due to high friction at the cutting interface [2]

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Conclusion