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<p>Built-up-edge (BUE) is recognized as one of the wear types that mainly develops during machining soft materials like aluminum and its alloys. The shape, height, and length of the BUE forms were considered as descriptors of wear textures to determine the underlying mechanism about the effect of BUE on machining indicators. In this context, experimental tests were conducted on Al2024-T6 using dry and MQL conditions to evaluate the lubrication effect on BUE formation, in addition to the basic turning parameters. A higher feed rate resulted in a height of the BUE of around 72–107% under dry conditions. In comparison, MQL resulted in a reduction of the BUE height of around 4–34%. Curved BUE on the tool with the highest accumulated material reduces forces and roughness, which is the main reason for elevated cutting temperatures under dry cutting. MQL-assisted turning outperformed the dry condition not only by diminishing or destroying the BUE formations, but also by creating better-formed chips, which reduced cutting forces, temperatures, and surface roughness under low feed rates.</p>

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Built-up-edge Formation and its Effect on Surface Topography and Machinability Indicators in Sustainable Minimum Quantity Lubrication Turning of Al2024-T6

  • 期刊论文

  • 发表日期：

    2025年10月6日

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  • Mustafa Kuntoğlu,
  • Rüstem Binali,
  • Havva Demirpolat,
  • Mayur Makhesana

摘要

Built-up-edge (BUE) is recognized as one of the wear types that mainly develops during machining soft materials like aluminum and its alloys. The shape, height, and length of the BUE forms were considered as descriptors of wear textures to determine the underlying mechanism about the effect of BUE on machining indicators. In this context, experimental tests were conducted on Al2024-T6 using dry and MQL conditions to evaluate the lubrication effect on BUE formation, in addition to the basic turning parameters. A higher feed rate resulted in a height of the BUE of around 72–107% under dry conditions. In comparison, MQL resulted in a reduction of the BUE height of around 4–34%. Curved BUE on the tool with the highest accumulated material reduces forces and roughness, which is the main reason for elevated cutting temperatures under dry cutting. MQL-assisted turning outperformed the dry condition not only by diminishing or destroying the BUE formations, but also by creating better-formed chips, which reduced cutting forces, temperatures, and surface roughness under low feed rates.