Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

Abstract

Micro-texturing has been widely proven to be an effective technology for achieving sustainable machining. However, the performance of micro-textured tools under different cooling conditions, especially their coupling effect on machined surface integrity, was scarcely reported. In this paper, the non-textured, linear micro-grooved, and curvilinear micro-grooved inserts were used to turn aluminum alloy 6061 under dry, emulsion, and liquid nitrogen cryogenic cooling conditions. The coupling effects of different micro-textures and cooling conditions on cutting force, cutting temperature, and machined surface integrity, including the surface roughness, work hardening, and residual stress, were revealed and discussed in detail. Results indicated that the micro-grooved tools, especially the curvilinear micro-grooved tools, not only reduced the cutting force and cutting temperature, but also improved the machined surface integrity. In addition, the micro-grooved tools can cooperate with the emulsion or liquid nitrogen to reduce the cutting force, cutting temperature, and improve the machined surface integrity generally, although the combination of emulsion cooling condition and micro-grooved tools generated negative coupling effects on cutting forces and surface work hardening. Especially, the combination of curvilinear micro-grooved cutting tools and cryogenic cooling condition resulted in the lowest cutting force and cutting temperature, which generated the surface with low roughness, weak work hardening, and compressive residual stress.

Keywords

Micro-grooved cutting tool / Cooling condition / Cutting force / Cutting temperature / Surface integrity

References

[1] Yang S, Wang T, Ren W, et al. Micro-texture design criteria for cemented carbide ball-end milling cutters. J Mech Sci Technol, 2020, 34: 127-136.

[2] Vignesh G, Barik D, Ragupathi P, et al. Experimental analysis on turning of AISI 4340 steel using non-textured, dimple textured and MoS₂ coated dimple textured carbide cutting inserts at the rack surface. Mater Today Proc, 2020, 33: 2616-2620.

[3] Qian X, Duan X, Zou J. Effects of different tool microstructures on the precision turning of titanium alloy TC21. Int J Adv Manuf Technol, 2020, 106: 5519-5526.

[4] Ahmed YS, Paiva JM, Arif AF, et al. The effect of laser micro-scale textured tools on the tool-chip interface performance and surface integrity during austenitic stainless-steel turning. Appl Surf Sci, 2020, 510: 145455.

[5] Sivaiah P, Ajay Kumar GV, Singh MM, et al. Effect of novel hybrid texture tool on turning process performance in MQL machining of Inconel 718 superalloy. Mater Manuf Process, 2020, 35: 61-71.

[6] Duan R, Wang G, Xing Y. Investigation of novel multiscale textures for the enhancement of the cutting performance of Al₂O₃/TiC ceramic cutting tools. Ceram Int, 2022, 48: 3554-3563.

[7] Ranjan P, Hiremath SS. Role of textured tool in improving machining performance: a review. J Manuf Process, 2019, 43: 47-73.

[8] Sasi R, Kanmani Subbu S, Palani IA. Performance of laser surface textured high speed steel cutting tool in machining of Al7075-T6 aerospace alloy. Surf Coat Technol, 2017, 313: 337-346.

[9] Sugihara T, Enomoto T. Development of a cutting tool with a nano/micro-textured surface-Improvement of anti-adhesive effect by considering the texture patterns. Precis Eng, 2009, 33: 425-429.

[10] Liu G, Huang C, Su R, et al. 3D FEM simulation of the turning process of stainless steel 17–4PH with differently texturized cutting tools. Int J Mech Sci, 2019, 155: 417-429.

[11] Liu G, Ozel T, Li J, et al. Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite element modelling of the cutting process. Int J Adv Manuf Technol, 2020, 110: 1327-1338.

[12] Machado AR, Silva L, Souza F, et al. State of the art of tool texturing in machining. J Mater Process Technol, 2021, 293: 117096.

[13] Elias JV, Venkatesh NP, Lawrence KD, et al. Tool texturing for micro-turning applications—an approach using mechanical micro indentation. Mater Manuf Process, 2021, 36(1): 84-93.

[14] Gupta MK, Song Q, Singh R, et al. Tribological behavior of textured tools in sustainable turning of nickel based super alloy. Tribiology Int, 2020, 155: 106775.

[15] Sivaiah P, Prasad MG, Singh MM, et al. Machinability evaluation during machining of AISI 52100 steel with textured tools under minimum quantity lubrication—a comparative study. Mater Manuf Process, 2020, 35(15): 1761-1768.

[16] Dinesh S, Senthilkumar V, Asokan P. Experimental studies on the cryogenic machining of biodegradable ZK60 Mg alloy using micro-textured tools. Mater Manuf Process, 2017, 32: 979-987.

[17] Liu G, Huang C, Zhao B, et al. Effect of machined surface integrity on fatigue performance of metal workpiece: a review. Chin J Mech Eng, 2021, 34: 118.

[18] Rajbongshi SK, Sarma DK. Performance parameters studies in machining of AISI D2 steel with dot-textured, groove-textured & non-textured cutting tool at the flank face. Int J Refract Met Hard Mater, 2019, 83: 104970.

[19] Palanisamy D, Balasubramanian K, Manikandan N, et al. Machinability analysis of high strength materials with cryo-treated textured tungsten carbide inserts. Mater Manuf Process, 2019, 34: 502-510.

[20] Musavi S, Sepehrikia M, Davoodi B, et al. Performance analysis of developed micro-textured cutting tool in machining aluminum alloy 7075-T6: assessment of tool wear and surface roughness. Int J Adv Manuf Technol, 2022, 119(5): 3343-3362.

[21] Yang S, Yu S, He C (2019) The surface integrity of titanium alloy when using micro-textured ball-end milling cutters. Micromachines 10(1):21. https://doi.org/10.3390/mi10010021

[22] Chen Y, Guo X, Zhang K, et al. Study on the surface quality of CFRP machined by micro-textured milling tools. J Manuf Process, 2019, 37: 114-123.

[23] Gupta MK, Song Q, Singh R et al (2020) Tribological behavior of textured tools in sustainable turning of nickel based super alloy. Tribiology Int 155:106775. https://doi.org/10.1016/j.triboint.2020.106775

[24] Samuel AU, Araoyinbo AO, Elewa RR et al (2021) Effect of machining of aluminium alloys with emphasis on aluminium 6061 alloy–a review. In: IOP conference series: materials science and engineering, IOP publishing 1107, international conference on engineering for sustainable world (ICESW 2020), 10–14 August, Ota, Nigeria. https://doi.org/10.1088/1757-899X/1107/1/012157

[25] Javidikia M, Sadeghifar M, Songmene V et al (2021) Low and high speed orthogonal cutting of AA6061-T6 under dry and flood-coolant modes: tool wear and residual stress measurements and predictions. Mater 14(15):4293. https://doi.org/10.3390/ma14154293

[26] Javidikia M, Sadeghifar M, Songmene V, et al. 3D FE modeling and experimental analysis of residual stresses and machining characteristics induced by dry, MQL, and wet turning of AA6061-T6. Macj Sci Technol, 2021, 25(6): 957-983.

[27] Javidikia M, Sadeghifar M, Songmene V, et al. Effect of turning environments and parameters on surface integrity of AA6061-T6: experimental analysis, predictive modeling, and multi-criteria optimization. Int J Adv Manuf Technol, 2020, 110: 2669-2683.

[28] Sadeghifar M, Sedaghati R, Jomaa W, et al. A comprehensive review of finite element modeling of orthogonal machining process: chip formation and surface integrity predictions. Int J Adv Manuf Technol, 2018, 96(9): 3747-3791.

[29] Sadeghifar M, Sedaghati R, Jomaa W, et al. Finite element analysis and response surface method for robust multi-performance optimization of radial turning of hard 300M steel. Int J Adv Manuf Technol, 2018, 94(5): 2457-2474.

[30] Zhao G, Wang D. Study on cutting simulation under different cooling conditions. Mach Electron, 2017, 35(3): 22-24.

[31] Matiga H, Viktor S, Franci P, et al. The procedure of solving the inverse problem for determining surface heat transfer coefficient between liquefied nitrogen and Inconel 718 workpiece in cryogenic machining. Procedia CIRP, 2017, 58(6): 617-622.

[32] Li C, Qiu X, Yu Z, et al. Novel environmentally friendly manufacturing method for micro-textured cutting tools. Int J Precis Eng Manuf Green Technol, 2020, 8: 1-12.

[33] Sugihara T, Kobayashi R, Enomoto T. Direct observations of tribological behavior in cutting with textured cutting tools. Int J Mach Tools Manuf, 2021, 168B: 103726.

[34] Liu J, Han R, Sun Y. Research on experiments and action mechanism with water vapor as coolant and lubricant in green cutting. Int J Mach Tools Manuf, 2005, 45: 687-694.

[35] Korkut I, Kasap M, Ciftci I, et al. Determination of optimum cutting parameters during machining of AISI 304 austenitic stainless steel. Mater Des, 2004, 25: 303-305.

[36] Özel T, Altan T. Determination of workpiece flow stress andfriction at the chip-tool contact for high-speed cutting. Int J Mach Tools Manuf, 2000, 40: 133-152.

[37] Duan PF. Research on cryogenic cutting technology for Aluminum alloy 6061, 2020, Jinan: University of Jinan

[38] Gong L, Bertolini R, Bruschi S, et al. Surface integrity evaluation when turning Inconel 718 alloy using sustainable lubricating-cooling approaches. Int J Precis Eng Manuf Green Tech, 2021, 9: 25-42.

[39] Mantle AL, Aspinwall DK. Surface integrity and fatigue life of turned gamma titanium aluminide. J Mater Process Technol, 1997, 72(3): 413-420.

[40] Liu G, Huang C, Sun S, et al. Effect of microstructure on high-speed cutting modified anti-fatigue performance of Incoloy A286 and titanium alloy TC17. Int J Adv Manuf Technol, 2021, 113(3): 855-866.

[41] Leadebal W Jr, Melo A, Oliveira A, et al. Effects of cryogenic cooling on the surface integrity in hard turning of AISI D6 steel. J Braz Soc Mech Sci Eng, 2018, 40(1): 15.

[42] Umbrello D, Micari F, Jawahir IS. The effects of cryogenic cooling on surface integrity in hard machining: a comparison with dry machining. CIRP Ann Manuf Technol, 2012, 61: 103-106.

[43] Gerstenmeyer M, Zanger F, Schulze V. Influence of complementary machining on fatigue strength of AISI 4140. CIRP Ann, 2018, 67(1): 583-586.

[44] Chen Z, Moverare J, Peng RL, et al. Surface integrity and fatigue performance of Inconel 718 in wire electrical discharge machining. Procedia CIRP, 2016, 45: 307-310.

Funding

National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809(52005281)

Natural Science Foundation of Shandong Province http://dx.doi.org/10.13039/501100007129(ZR2020QE181)

Key Technology Research and Development Program of Shandong http://dx.doi.org/10.13039/100014103(2018GGX03010)

State Key Laboratory of High Performance Complex Manufacturing http://dx.doi.org/10.13039/501100011352(Kfkt2020-06)