Experimental investigation of minimum quantity lubrication on tool wear in aluminum alloy 6061-T6 using different cutting tools

摘要

In manufacturing, a great challenge are currently being faced which is competitive marketing place due to manufacturing environment, low costs, aim for high rates of productivity and also with high quality as required by the customers. Aluminum alloys are competitively being used in current industries especially in automotive and aeronautics sector. This study is to experimental investigation of minimum quantity lubricant (MQL) for the end milling machining characteristics towards the tool wear during machining aluminum alloy 6061-T6. The process parameters including the cutting speed, depth of cut and feed rate are selected for study. To develop a model of process optimization based on the response surface method. This experiment was conducted based on central composite design method. Three types of tools used in this experiment which are coated CTP 2235, coated CTP 1235 and uncoated CTW 4615 carbide tool. For every cuts, the tool wear was checked under scanning electron microscope. The tool wear data was then used to make the quadratic models. A number of graphs were plotted to find the connections between input parameter and tool wear. Based on the data generated by multi objective optimization, an optimized tool wear data was made to identify the best inserts and also the compatibility with MQL. It was identified that the insert does not have much tool wear and all of them are in range of below 0.3 mm. Uncoated carbide CTW 4615 was chosen as the best insert at the end of this experiment from the optimized data.