Abstract
The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.
Highlights
The aluminum alloys are widely applied in various industries due to their ability to combine strength and lightness [1]
The use of increased cutting parameters (f = 0.2 mm/rev; vc = 1200 m/min) causes a 6-fold shortening of tool life and a 5-fold decrease in the cutting path over the tool life, compared to the values obtained during turning with f = 0.2 mm/rev; vc = 1200 m/min. This indicates that the moderate growth of a grooving productivity with DDCC inserts can lead to the intense decline in tool life
The carried out tests included the inspections of the tool wear and assessment of tool life
Summary
The aluminum alloys are widely applied in various industries due to their ability to combine strength and lightness [1]. Cemented carbide tools are very often applied in the turning of soft aluminum alloys with high cutting speeds (600–800 m/min), as well as with positive rake angles (6◦ –20◦ ). This information was confirmed during the research conducted by Torpov et al [55]. The tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. The results can be selected for an effective selection of machining parameters during cutting of Al-Si alloys with DDCC materials
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