Analysis of Surface Integrity and Formation of Material Side Flow in Dry and Wet Machining of Aluminum Alloy

A.B. Hadzley, A.A. Anis, M.N. Farizan, M.H. Osman, T. Norfauzi, S. Noorazizi

Abstract


This paper presents the surface integrity of aluminum alloy under dry and wet conditions. Bars of aluminum alloy with consistent size have been machined at different cutting speeds and feed rates at very short cutting time. The comparison between dry and wet cutting have been assessed based on the surface integrity, determined by the surface roughness value and observation of surface profiles. The result shows that machining in dry condition produces better surface finish where the coolants did not give a big impact on the surface roughness especially at the higher cutting speed. Further observation at the surface profile of dry cutting shows that more formation of material side flow appeared on the machined surface that could decreased the surface roughness value. Surface generated under bot dry and wet conditions appeared with well-defined and free from other damage such as cracking or tearing.

Full Text:

PDF

References


K. S. Sundara Rao and K. V. Allamraju, “Effect on Micro-Hardness and Residual Stress in CNC Turning Of Aluminium 7075 Alloy,” Materials Today: Proceedings, vol. 4, no. 2, pp. 975-981, 2017.

M. C. Santos, A.R. Machado, W.F. Sales, M.A.S. Barrozo and E.O. Ezugwu, “Machining of Aluminum alloys: A Review”, International Journal of Advance Manufacturing Technology, volume 86, no. 9–12, pp. 3067–3080, 2016.

M. A. Kamely M.Y. Noordin, A.Y. Bani Hashim, S.H. Yahya and M.M.P. Dan, “The performance of low cost cutting tools when machining hardened steel of 60 HRC,” Journal of Advanced Manufacturing Technology, vol. 6, no. 1, pp. 1-12, 2012.

M. Imran, P. T. Mativenga, A. Gholinia and P. J. Withers, “Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickel base superalloys,”International Journal of Machine Tools and Manufacture, vol. 76, pp. 49-60, 2014.

I. Yahya, “An Experimental Investigation on Effect of Cutting Fluids in Turning with Coated Carbides Tool, Journal of Mechanical Engineering, vol. 56, no. 3, pp.1-7, 2010.

J. Kouam, M. Balazinski, P. Hendrick, V. Songmene, Dry, Semi Dry and Wet Machining of 6061-T6 Aluminium Alloy. London: INTECH Open Acsess Publisher, 2012.

M. Grover and Z.A. Khan, “The comparison on tool wear, surface finish and geometric accuracy when turning EN8 steel in wet and dry conditions,” in Proceedings of the World Congress on Engineering, London, 2014, pp. 1093–1097.

R.K. Suresh, G. Krishnaiah and P. Venkataramaiah, “An experimental investigation to compare the effectiveness of coated DNMG inserts during turning of AISI D3 steel with castor oil as cutting fluid using desirability function analysis”, International Journal of Materials and Biomaterials Applications, vol. 5, no. 2, pp.17-24, 2015.

N.I. Galanis, D.E. Manolakos and N.M. Vaxevanidis, “Comparison between dry and wet machining of stainless steel”, in 3rd International Conference on Manufacturing Engineering, Greece, 2008, pp. 91–97.

P. J. Liew, U.S. Hashim and M.N.A Rahman, “Effect of Chilled Air Coolant on Surface Roughness and Tool Wear When Machining 2205 Duplex Stainless Steel”, Journal of Advanced Manufacturing Technology, vol. 11, no. 1, pp. 61-68, 2017.

A.B. Hadzley, M.R. Nurul Fatin, R. Izamshah, S. Nur Izan, A. Sarah and S. Sivaraos, “Surface Integrity of a High Speed Milling FC300 Gray Cast Iron”, Applied Mechanics and Materials, vol. 456-466, pp. 642–646, 2014.

M. Dogra, V.S. Sharmab and J. Durejac, “Effect of tool geometry variation on finish turning”, Journal of Engineering Science and Technology Review, vol. 4, no. 1, pp. 1-13, 2011.

M. Singh, D. Deepak and M. Singla, “A comprehensive study of operational condition for turning process to optimize the surface roughness of object,” International Journal of Emerging Technology, vol. 1, no. 1, pp. 97–101, 2010.

A.Z. Tomkiewicz, “Analysis of surface roughness parameters achieved by hard turning with the use of PCBN tools,” Estonian Journal of Engineering, vol. 17, no. 1, pp. 88–99, 2011.

R. Waleed and G. Saurav, “Advances in the surface defect machining (SDM) of hard steels,” Wear, vol. 302, pp. 1124-1135, 2013.




© Journal of Advanced Manufacturing Technology