Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets

Bünyamin Aksakal; Faruk Karaca

doi:10.3139/120.110758

Article

Influence of cutting parameters and TiBN coating material on the drilling of Al6061-T4 sheets

Bünyamin Aksakal and Faruk Karaca

Published/Copyright: July 3, 2015

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From the journal Materials Testing Volume 57 Issue 7-8

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.

§Correspondence Address Bunyamin Aksakal, Yildiz Technical University, Dept. of Metallurgy and Mater Eng., Davutpasa Campus, Istanbul, Turkey, E-mail: baksakal@yildiz.edu.tr; baksakal2@gmail.com, fkaraca@firat.edu.tr; faruk23karaca@gmail.com

Bünyamin Aksakal, born in 1964, has professional experience in materials, materials processing, biomaterials and their coatings. Presently, he has a position as Senior Lecturer (Professor) and is the Head of the Metallurgy and Materials Engineering Department at the Yildiz Technical University, Istanbul, Turkey.

Faruk Karaca, born in 1978, has professional experience in mechanics and biomechanics, biomaterials and machinability. Presently, he is Co-head) of the Mechanical Engineering Department of the Technology Faculty at Firat University, Elazig in Turkey.

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Published Online: 2015-07-03

Published in Print: 2015-07-15

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https://doi.org/10.3139/120.110758