Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured unde...

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Bibliographic Details
Published in:Proceedings of the Institution of Mechanical Engineers. Part B, Journal of engineering manufacture Journal of engineering manufacture, 2020-02, Vol.234 (3), p.610-620
Main Authors: Pham, Thi-Hoa, Nguyen, Duc-Toan, Banh, Tien-Long, Tong, Van-Canh
Format: Article
Language:English
Subjects:
Aluminum alloys
Aluminum base alloys
Chip formation
Contact length
Cutting parameters
Cutting speed
Face milling
Feed rate
High speed machining
Milling industry
Morphology
Plastic deformation
Surface roughness
Vibration measurement
Workpieces
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Summary:In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured under varying cutting conditions (cutting speed, feed rate, and depth of cut). The characteristics of chip morphology were observed using scanning electron microscope. Experimental results showed that the increasing cutting speed reduced the tool–chip contact length, the workpiece vibration, and the surface roughness. The tool–chip contact length, the workpiece vibration, and the surface roughness were all increased with increasing cutting depth and feed rate. The results of chip morphology showed that the chips with serrated form were generated under high-speed cutting conditions. Moreover, scratch lines, plastic deformation cavities, and local molten chip material were observed on the slide chip surface.
ISSN:0954-4054
2041-2975
DOI:10.1177/0954405419863221