Experimental Study on Surface Integrity, Dimensional Accuracy, and Micro-Hardness in Thin-Wall Machining of Aluminum Alloy

Bolar, Gururaj and Joshi, Srikrishna N (2018) Experimental Study on Surface Integrity, Dimensional Accuracy, and Micro-Hardness in Thin-Wall Machining of Aluminum Alloy. International Journal of Materials Forming and Machining Processes, 5 (2). pp. 13-31. ISSN 2334-4563

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Abstract

This article presents an experimental investigation into the influence of process parameters viz. feed per tooth, axial depth of cut on milling force, surface finish, wall deflection and micro-hardness during thin-wall machining of an aerospace grade aluminum alloy 2024-T351. Results revealed that the process parameters significantly influence the surface finish and dimensional accuracy of machined thin-walls. High feed rate promoted the formation of built-up-edge (BUE). Combination of high feed and axial depth of cut aided in catastrophic failure of tools. Surface damages such as material plucking, material shearing, material adhesion and deformed feed mark layer formation were observed. Axial depth of cut negatively influenced the wall deflection leading to loss of dimensional accuracy. Interestingly, the micro-hardness at the machined surface was found to be lower than that of the bulk material hardness. These results will be useful in selection of suitable process parameters for quality and precise machining of thin-wall parts.

Item Type: Article
Uncontrolled Keywords: Axial Depth of Cut, Built-Up-Edge, Chatter, Feed Rate, Milling Force, Surface Roughness, Tool Diamet
Subjects: Engineering > MIT Manipal > Mechanical and Manufacturing
Depositing User: MIT Library
Date Deposited: 13 Nov 2018 07:02
Last Modified: 13 Nov 2018 07:02
URI: http://eprints.manipal.edu/id/eprint/152246

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