Exploring Machining Capabilities of Al-Mg2Si-Si Rod with Coated Carbide Insert
摘要
Al-Mg2Si-Si composite is a newly developed material having low density and can be applied in aerospace and other automobile industries. To make a product out of this composite using machining operation, appropriate cutting tool, process parameters and environment are to be employed to obtain desired machinability. Dry as well as wet turning have been carried out on Al-Mg2Si-Si composite using a narrow groove-type carbide insert under different conditions. Turning tests are carried out on this composite material at 5 levels of cutting velocity and feed with 1.5 mm depth of cut. Castrol Alusol is applied as the cutting fluid. Examining influence of these factors in turning Al-Mg2Si-Si composite, valuable insights can be gained regarding its machinability and suitability for specific applications. In this experiment, effects of the two factors on cutting force components, chip formation and quality of work surface have been investigated in dry and wet environment. Feed is detected to affect surface quality in both conditions as expected followed by cutting velocity. In wet condition, good surface quality without any built-up edge formation has been obtained unlike that in dry condition. Therefore, wet machining using Castrol Alusol as the cutting fluid may be utilized in the industry along with setting 160 m/min cutting velocity and 0.06 mm/rev feed. It has been found that wet conditions provide good tool performance under a variety of cutting conditions.