Experimental analysis and optimisation of tool wear in dry machining of aluminium alloys
Wear 255 (2003) 1359–1368
Experimental analysis and optimisation of tool wear in dry machining of aluminium alloys
M. Nouari∗ , G. List, F. Girot, D. Coupard
Ecole Nationale Supérieure d’Arts et Métiers, Centre d’Enseignement et de Recherche de Bordeaux,
Laboratoire Matériaux Endommagement Fiabilité et Ingénierie des Procédés, Esplanade des Arts et Métiers, 33405 Talence Cedex, France
Abstract
In machining, coolants and lubricants improve machinability, increase productivity by reducing the tool wear and extend the tool life.
However, the use of cutting fluids in metal working operations may seriously degrade the quality of the environment. Consequently, many governments recommend the manufacturers to reduce the volume and the toxicity of their cutting fluids. Up to now, dry machining has remained a real challenge for the industrial world, particularly in aerospace engineering. The experimental approach taken in this study resulted in the development of both optimised tool geometry and optimised cutting conditions for drilling aluminium alloys without the need for lubrication. The experimental investigations were carried out with WC–Co cemented carbide drills. The use of diamond as coating material allowed to extend the tool life. The combination of the optimised tool geometry and the cutting conditions entails a high surface quality, a good dimensional accuracy of the machined material and ensures a long lifetime to the drill. Besides, a numerical calculation with
Third Wave AdvantEdgeTM finite element software was used to predict the tool–chip interface temperature, which is the major parameter inducing tool wear in dry drilling.
© 2003 Elsevier Science B.V. All rights reserved.
Keywords: Dry machining; Tool wear; Adhesion wear; Optimised drill geometry
1. Introduction
Machining aerospace aluminium alloys (series 20xx) with conventional tools is not carried out without any difficulties. These materials tend to adhere to the tool surface and
Experimental analysis and optimisation of tool wear in dry machining of aluminium alloys
M. Nouari∗ , G. List, F. Girot, D. Coupard
Ecole Nationale Supérieure d’Arts et Métiers, Centre d’Enseignement et de Recherche de Bordeaux,
Laboratoire Matériaux Endommagement Fiabilité et Ingénierie des Procédés, Esplanade des Arts et Métiers, 33405 Talence Cedex, France
Abstract
In machining, coolants and lubricants improve machinability, increase productivity by reducing the tool wear and extend the tool life.
However, the use of cutting fluids in metal working operations may seriously degrade the quality of the environment. Consequently, many governments recommend the manufacturers to reduce the volume and the toxicity of their cutting fluids. Up to now, dry machining has remained a real challenge for the industrial world, particularly in aerospace engineering. The experimental approach taken in this study resulted in the development of both optimised tool geometry and optimised cutting conditions for drilling aluminium alloys without the need for lubrication. The experimental investigations were carried out with WC–Co cemented carbide drills. The use of diamond as coating material allowed to extend the tool life. The combination of the optimised tool geometry and the cutting conditions entails a high surface quality, a good dimensional accuracy of the machined material and ensures a long lifetime to the drill. Besides, a numerical calculation with
Third Wave AdvantEdgeTM finite element software was used to predict the tool–chip interface temperature, which is the major parameter inducing tool wear in dry drilling.
© 2003 Elsevier Science B.V. All rights reserved.
Keywords: Dry machining; Tool wear; Adhesion wear; Optimised drill geometry
1. Introduction
Machining aerospace aluminium alloys (series 20xx) with conventional tools is not carried out without any difficulties. These materials tend to adhere to the tool surface and
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