Failure Analysis And Mechanism Of Car Carbide Carving In Green Turning The Automotive Material Al 6061 -t6

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Failure Analysis and Mechanism of Car Carbide Carving in Green Turning the Automotive Material Al 6061-T6

Introduction

The manufacturing industry has seen a significant shift towards the use of dry machining techniques for producing automotive components with aluminum 6061-T6. This method offers several advantages, including reduced environmental pollution and lower risks to operators. However, dry cutting also presents its own set of challenges, such as friction between the material and cutting tools, chip formation mechanisms, chip flow, and cutting temperatures. In this study, we focus on the use of uncoated and coated carbide carving tools in the process of turning, with the aim of understanding the mechanism of failure and the characteristics of chisel wear during the cutting process.

Background

The use of dry cutting in the manufacturing industry has gained popularity in recent years due to its numerous benefits. One of the primary advantages of dry cutting is the reduction of environmental pollution, as it eliminates the need for coolant fluids. Additionally, dry cutting reduces the risk of operators being exposed to fog from cutting liquids, making it a safer option. However, despite its benefits, dry cutting also presents several challenges, including friction between the material and cutting tools, chip formation mechanisms, chip flow, and cutting temperatures.

Methodology

This study involved the use of uncoated and coated carbide carving tools, specifically the ISO K10 carbide chisel and the Tin Coated ISO K10 carbide chisel. The experimental process was carried out using a CNC TU 2A lathe with an incremental design to observe damage and wear on the cutting tool. The results of the study showed that the ISO K10 carbide chisel failed in the form of fragile broken, plastic deformation, flank wear, flanking, and excessive chipping.

Results

The results of the study showed that the ISO K10 carbide chisel failed in the form of fragile broken, plastic deformation, flank wear, flanking, and excessive chipping. This failure mode arises due to a slower chip current than the speed of cutting, as well as a smaller chip (RO) radius than the Breaker Chip (R) radius. The resulting chip tends to be twisted and messy helical-shaped, with a length of more than 5 cm long, and curved chip flow can cause a buildup of material in the wear of the aus chisel, leading to flaking and chipping.

Measurement of Flank Wear

Measurement shows that the maximum flank wear in the ISO K10 carbide chisel is in the C zone with a thickness of 0.035 mm. Conversely, in K10 Tin car carving chisels, no flanking flank and wear are found lower (0.023 mm), showing performance which is 34.29% better than ISO K10. In cutting conditions 300 ml/minute with a depth of 0.8 mm and the feed rate of 0.14 mm/rev, the two cutting tools show the worst performance.

Critical Condition for Failure

From the perspective of the primary shear angle and chip radius, the critical condition that causes the failure mode of the two cut chisel is identified at angle α = 24.68-33.53 ° and Ro = 0.129-0.447 mm. The surface roughness aspect is also analyzed, where the RA value for the ISO K10 Tin chisel is better than the ISO K10 for all cutting conditions tested, with a surface roughness range of 0.75 - 9.27 μm for ISO K10 and 0.63 - 8.60 μm for ISO K10 Tin. This shows that the tin layer functions as a more effective cooler and solid lubricant.

Conclusion

Overall, this study provides an important insight into the mechanism of failure and wear on carbide chisel during the dry cutting process, and emphasizes the importance of choosing the right type of cutting tool to improve the efficiency and final outcome of the process of turning the automotive material, especially aluminum 6061-T6. By optimizing the parameter of cutting and selection of tools, the industry can minimize losses due to wear and improve the quality of the final products produced.

Recommendations

Based on the findings of this study, the following recommendations are made:

  • The use of coated carbide carving tools, such as the Tin Coated ISO K10 carbide chisel, can improve the performance and efficiency of the dry cutting process.
  • The selection of the right type of cutting tool should be based on the specific requirements of the material being cut, as well as the cutting conditions.
  • The optimization of the parameter of cutting, such as the cutting speed, feed rate, and depth of cut, can also improve the performance and efficiency of the dry cutting process.
  • Further research is needed to investigate the effects of different cutting tool materials and coatings on the performance and efficiency of the dry cutting process.

Future Research Directions

Future research should focus on the following areas:

  • Investigating the effects of different cutting tool materials and coatings on the performance and efficiency of the dry cutting process.
  • Developing new cutting tool materials and coatings that can improve the performance and efficiency of the dry cutting process.
  • Investigating the effects of different cutting conditions, such as cutting speed, feed rate, and depth of cut, on the performance and efficiency of the dry cutting process.
  • Developing new methods for optimizing the parameter of cutting to improve the performance and efficiency of the dry cutting process.
    Q&A: Failure Analysis and Mechanism of Car Carbide Carving in Green Turning the Automotive Material Al 6061-T6

Q: What is the main objective of this study?

A: The main objective of this study is to understand the mechanism of failure and the characteristics of chisel wear during the dry cutting process of automotive material Al 6061-T6 using uncoated and coated carbide carving tools.

Q: What are the benefits of using dry cutting in the manufacturing industry?

A: The benefits of using dry cutting in the manufacturing industry include reduced environmental pollution, lower risks to operators, and improved efficiency.

Q: What are the challenges of using dry cutting in the manufacturing industry?

A: The challenges of using dry cutting in the manufacturing industry include friction between the material and cutting tools, chip formation mechanisms, chip flow, and cutting temperatures.

Q: What types of carbide carving tools were used in this study?

A: The study used uncoated and coated carbide carving tools, specifically the ISO K10 carbide chisel and the Tin Coated ISO K10 carbide chisel.

Q: What were the results of the study in terms of flank wear?

A: The results of the study showed that the maximum flank wear in the ISO K10 carbide chisel was in the C zone with a thickness of 0.035 mm, while the Tin Coated ISO K10 carbide chisel showed no flanking flank and wear, with a thickness of 0.023 mm.

Q: What is the critical condition that causes the failure mode of the two cut chisel?

A: The critical condition that causes the failure mode of the two cut chisel is identified at angle α = 24.68-33.53 ° and Ro = 0.129-0.447 mm.

Q: What is the surface roughness aspect of the study?

A: The surface roughness aspect of the study showed that the RA value for the ISO K10 Tin chisel was better than the ISO K10 for all cutting conditions tested, with a surface roughness range of 0.75 - 9.27 μm for ISO K10 and 0.63 - 8.60 μm for ISO K10 Tin.

Q: What are the recommendations of the study?

A: The recommendations of the study include the use of coated carbide carving tools, such as the Tin Coated ISO K10 carbide chisel, to improve the performance and efficiency of the dry cutting process, and the optimization of the parameter of cutting to minimize losses due to wear and improve the quality of the final products produced.

Q: What are the future research directions of the study?

A: The future research directions of the study include investigating the effects of different cutting tool materials and coatings on the performance and efficiency of the dry cutting process, developing new cutting tool materials and coatings that can improve the performance and efficiency of the dry cutting process, and investigating the effects of different cutting conditions on the performance and efficiency of the dry cutting process.

Q: What are the implications of the study for the manufacturing industry?

A: The implications of the study for the manufacturing industry are that the use of coated carbide carving tools and the optimization of the parameter of cutting can improve the performance and efficiency of the dry cutting process, and minimize losses due to wear and improve the quality of the final products produced.

Q: What are the limitations of the study?

A: The limitations of the study include the use of a limited number of cutting tool materials and coatings, and the use of a limited number of cutting conditions.

Q: What are the future applications of the study?

A: The future applications of the study include the use of coated carbide carving tools in the manufacturing industry, and the optimization of the parameter of cutting to improve the performance and efficiency of the dry cutting process.