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Research Papers

Experimental Assessment of Laser Textured Cutting Tools in Dry Cutting of Aluminum Alloys

[+] Author and Article Information
Youqiang Xing

Key Laboratory of High Efficiency
and Clean Mechanical Manufacture of MOE,
Department of Mechanical Engineering,
Shandong University,
17923 Jingshi Road,
Jinan 250061, China;
Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: xyq1102006@126.com

Jianxin Deng

Key Laboratory of High Efficiency and Clean
Mechanical Manufacture of MOE,
Department of Mechanical Engineering,
Shandong University,
Jinan 250061, China
e-mail: jxdeng@sdu.edu.cn

Xingsheng Wang

Department of Mechanical Engineering,
Nanjing Agricultural University,
Nanjing 210031, China;
Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: xingshengwang@njau.edu.cn

Kornel Ehmann

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: k-ehmann@northwestern.edu

Jian Cao

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: jcao@northwestern.edu

1Corresponding author.

Manuscript received July 8, 2015; final manuscript received December 9, 2015; published online March 8, 2016. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 138(7), 071006 (Mar 08, 2016) (10 pages) Paper No: MANU-15-1341; doi: 10.1115/1.4032263 History: Received July 08, 2015; Revised December 09, 2015

To improve the friction conditions and reduce adhesion at the tool's rake face in dry cutting of aluminum alloys, three types of laser surface textures were generated on the rake face of cemented carbide tools. Orthogonal dry cutting tests on 6061 aluminum alloy tubes were carried out with the textured and conventional tools (CT). The effect of the texture geometry on the cutting performance was assessed in terms of cutting forces, friction coefficient, chip compression ratio, shear angle, tool adhesions, chip morphology, and machined surface quality. The results show that the textured tools can improve the cutting performance at low cutting speeds, and that the tool with rectangular type of textures is the most effective.

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Figures

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Fig. 1

Schematic diagram and optical image of a laser textured tool

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Fig. 2

Surface morphologies and geometries of the textures

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Fig. 3

Schematic diagram and experimental image of the cutting test

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Fig. 4

Variations of dynamic cutting forces of different tools with cutting time at the speed of 54.9 m/min

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Fig. 5

Effect of textured tools on cutting forces at different speeds: (a) feed force and (b) main cutting force

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Fig. 6

Effect of textured tools on friction coefficient at different cutting speeds

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Fig. 7

Variation of chip compression ratio and shear angle at different cutting speeds

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Fig. 8

Rake face of different tools after 11.7 and 87.8 m cutting at the speed of 54.9 m/min

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Fig. 9

SEM images of the rake face of CT and TT-R tools after 87.8 m dry cutting at the speed of 54.9 m/min. (a): CT, (b) and (c): TT-R.

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Fig. 10

Adhesion height on the rake face of different tools after 87.8 m dry cutting at the speed of 54.9 m/min

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Fig. 11

Morphologies and surface roughness of the machined surface with different tools at the speed of 54.9 m/min

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Fig. 12

Observation of the cutting process using a high-speed camera with different tools at the speed of 54.9 m/min

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Fig. 13

Typical chips with different tools at the speed of 54.9 m/min

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Fig. 14

SEM images of typical chips for CT (a) and TT-R (b) tools at the speed of 54.9 m/min

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