Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets
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Bünyamin Aksakal
Abstract
In this study, the machinability of Al6061-T4 aluminum alloy sheets was experimentally investigated by drilling process using uncoated HSS and TiBN coated HSS drill bits. In experiments, the tool feed rate, cutting speed and drill diameter were varied to explore their effects on surface roughness of the machined holes, hole circularity, chip and burr formation, respectively. The hole qualities were determined by using an atomic force microscope (AFM) and a profilometer. The measured values were also analyzed statistically. It was demonstrated that the surface roughness increased with decreasing cutting speed and increased with feed rate of the tool. TiBN coated drill bits provided better hole surfaces compared to uncoated drill bits. The most significant factor on the surface roughness was found to be the cutting speed while the coating material was the second significant factor. In addition, the burst-type burr formations were observed only at a 4 mm drill diameter and high drill speeds with uncoated tools, while the TiBN coated tools gave burr-free surfaces.
Kurzfassung
In der diesem Beitrag zugrunde liegenden Studie wurde die maschinelle Bearbeitbarkeit von Aluminiumblechen der Legierung Al6061-T4 beim Bohrprozess experimentell untersucht, wobei unbeschichtete und TiBN-beschichtete HSS-Bohrer eingesetzt wurden. In den Experimenten wurde die Werkzeugvorschubrate, die Schnittgeschwindigkeit und der Bohrerdurchmesser variiert, um deren Auswirkungen auf die Oberflächenrauheit und die Rundheit der bearbeiteten Bohrungen sowie die Span- und Gratausbildung zu untersuchen. Die Bohrungsqualität wurde unter Einsatz eines Rasterkraftmikroskops (Atomic Force Microscope (AFM)) und eines Profilmessers ermittelt. Die gemessenen Werte wurden außerdem statistisch analysiert. Es wurde gezeigt, dass die Oberflächenrauheit mit abnehmender Schnittgeschwindigkeit und mit zunehmender Vorschubrate ansteigt. Die TiBN-beschichteten Bohrer ergaben bessere Bohrungsoberflächen im Vergleich zu den unbeschichteten Bohrern. Als signifikantester Einfluss auf die Oberflächenrauheit erwies sich die Schnittgeschwindigkeit, während das Beschichtungsmaterial hinsichtlich der Signifikanz an zweiter Stelle rangierte. Darüber hinaus wurde die Span- und Gratausbildung nur bei den Bohrern mit 4 mm Durchmesser beobachtet und die hohen Bohrgeschwindigkeiten mit den unbeschichteten sowie mit den TiBN-beschichteten Bohrern ergaben gratfreie Oberflächen.
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© 2015, Carl Hanser Verlag, München
Artikel in diesem Heft
- Fachbeiträge/Technical Contributions
- Oxidation behavior of 26Cr-16Ni and AISI 309 austenitic stainless steels in air flow at 1,173 K
- Temperature effects on tensile properties of laser sintered polyamide 12
- Friction stir spot welding of aluminum alloys: A recent review
- Numerical simulation and experimental validation of angular distortion and residual stresses in a T-joint
- Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets
- Testing of pipe sections
- Effect of Ti-Al-O inclusions on the formation of intragranular acicular ferrite
- Impact behavior of multi-layer carbon skin composite sandwich panels with 3D spacer fabric
- Effect of sintering temperature on transverse rupture strength of hot pressed Cu-TiC composites
- Grey-based fuzzy algorithm for the optimization of the ball burnishing process
- Analysis of influential factors for ultrasonic disc size evaluation
- Evaluation of double channel GMAW fillet welds of low carbon steel using solid wire
- Friction behavior of granite powder added brake pads
- Prediction of the elastic modulus of SWCNT/epoxy composite based on the micromechanics
- Modernization of a surface grinding machine with a novel ball screw drive
- Machining of an involute worm gear drive using the surface definition procedure
Artikel in diesem Heft
- Fachbeiträge/Technical Contributions
- Oxidation behavior of 26Cr-16Ni and AISI 309 austenitic stainless steels in air flow at 1,173 K
- Temperature effects on tensile properties of laser sintered polyamide 12
- Friction stir spot welding of aluminum alloys: A recent review
- Numerical simulation and experimental validation of angular distortion and residual stresses in a T-joint
- Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets
- Testing of pipe sections
- Effect of Ti-Al-O inclusions on the formation of intragranular acicular ferrite
- Impact behavior of multi-layer carbon skin composite sandwich panels with 3D spacer fabric
- Effect of sintering temperature on transverse rupture strength of hot pressed Cu-TiC composites
- Grey-based fuzzy algorithm for the optimization of the ball burnishing process
- Analysis of influential factors for ultrasonic disc size evaluation
- Evaluation of double channel GMAW fillet welds of low carbon steel using solid wire
- Friction behavior of granite powder added brake pads
- Prediction of the elastic modulus of SWCNT/epoxy composite based on the micromechanics
- Modernization of a surface grinding machine with a novel ball screw drive
- Machining of an involute worm gear drive using the surface definition procedure
