CUTTING FORCES AND CHIP FORMATION IN ALUMINUM ORTHOGONAL MACHINING

CUTTING FORCES AND CHIP FORMATION IN ALUMINUM ORTHOGONAL MACHINING

Abstract:

Over the past century, extensive research has delved into the exploration and comprehension of various machining processes, aimed at enhancing economic outcomes, including cost-effectiveness and productivity. However, numerous aspects related to cutting processes and their performance remain elusive, impeding the full optimization of these processes. Cutting is a complex procedure characterized by substantial stresses and plastic deformations. The elevated compressive forces and frictional interactions at the tool face generate considerable cutting forces, denoted as F, which are fundamental for assessing the requisite power in machining, such as the selection of an electric motor. Furthermore, they play a pivotal role in the dimensioning of machine tool components and the tool body, exerting a significant influence on the deformation of the workpiece being machined, its dimensional precision, chip formation, and the overall stability of the machining system.

This research endeavor focuses on investigating the impact of the feed rate, tool rake angle, and depth of cut on the primary cutting force and chip morphology during the turning process, utilizing aluminum alloy 6061 as the workpiece material. In total, 27 meticulously executed experiments were carried out to gauge the main cutting force (Fc). These experiments encompassed varying cutting depths of 0.5mm, 1.0mm, and 1.5mm, along with cutting speeds of 71, 90, and 119 m/min. Additionally, three distinct feed rates were employed: 0.15mm/rev, 0.20mm/rev, and 0.25mm/rev, in conjunction with three different rake angles of 18°, 20°, and 28°.

Throughout the course of experimentation, the chips produced were systematically collected and analyzed alongside the primary cutting forces. The experimental results elucidated a noticeable trend wherein the main cutting force exhibited an upward trajectory with increasing feed rates ranging from 0.05mm/rev to 0.7mm/rev. Conversely, there was a discernible declining trend in the main cutting force as the rake angle augmented from 0° to 20°. Furthermore, observations hinted at the occurrence of deformation during the machining process. Despite the generally continuous nature of the chips, their length exhibited a decrease with escalating cutting speeds and feed rates. Notably, the experiment yielded optimal results when utilizing a 12° rake angle for the specimen.

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