Performance evaluation of different carbide inserts in turning of newly developed Al‐12Si‐0.1Sr alloy

Abstract

AbstractAn Al‐12Si‐0.1Sr alloy ingot was manufactured using a permanent mold casting technique. The microstructure and mechanical properties of this alloy were researched. Effects of different cutting conditions (cutting speed‐V: 200 m/min, 300 m/min, and 400 m/min and feed rate‐f: 0.05 mm/rev, 0.1 mm/rev, and 0.15 mm/rev) on the cutting force (F) and surface roughness (Ra) during machining using uncoated and physical vapor deposition‐ titanium aluminum nitride coated carbide inserts were also revealed. Microstructure of the alloys consists of α phase, intermetallic δ and Al4Sr phases, thin spherical eutectic, and irregular coarse‐shaped primary silicon particles. Cutting force and surface roughness decreased with the increased cutting speed during turning with uncoated, and titanium aluminum nitride coated inserts while they increased feed rate. A built‐up edge and built‐up layer were formed in both cutting inserts. The built‐up edge and built‐up layer decreased with increasing cutting speed and increased feed rate. The cutting force, surface roughness, built‐up edge, and built‐up layer were lower in uncoated inserts compared to the titanium aluminum nitride coated inserts.