Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy
Abstract
:1. Introduction
Material | Tool Details | Input Parameters | Analyzed Outputs | Refs |
---|---|---|---|---|
Al6061 drilling | Uncoated HSS Helix angle: 45° Point angle: 100°, 110°, 118° Drill diameter: 8, 10, and 12 mm | Feed rate: 0.3, 0.5, 0.6 (mm/rev) Spindle speed: 600, 800, 1000 (rpm) | SR, BH, BT, CIRC | [19,21] |
AI6061 drilling | TiN-HSS Point angle: 118° Drill diameter: 8 mm | Feed rate: 0.04, 0.08 (mm/rev) Spindle speed: 1000, 1500, 2000 (rpm) | CF, TW, BH, BT, CIRC, CHF | [13] |
Al6061/20%SiCp composite drilling | Tipped carbide Point angle: 90°, 118°, 135° Drill diameter: 10 mm | Feed rate: 0.12, 0.16, 0.20 (mm/rev) Spindle speed: 900, 1120, 1330 (rpm) | CF, SR | [20] |
Al6061/B4C composite milling | Uncoated carbide inserts Cutting diameter: 40 mm | Feed rate: 0.08, 0.1, 12, 0.16 (mm/tooth) Milling speed: 220, 285, 370, 480 (mm/min) | SR, PO | [16] |
Al6061-T6 drilling | Uncoated HSS Drill diameter: 11.7 mm | Feed rate: 0.2, 0.3, 0.4 (mm/rev) Cutting speed: 60, 75, 100 (rpm) | HS, CIRC, SR | [26] |
Al6061/SiC/B4C/t lc composite drilling | Uncoated HSS Drill diameter: 6, 7, 8 mm | Feed rate: 15, 25, 35 (mm/min) Cutting speed: 750, 1000, 1250 (rpm) | CF, SR, CIRC | [15] |
Al2124/20 % B4C end milling | Uncoated carbide | Feed rate: 0.1, 0.2, 0.3 (mm/rev) Cutting speed: 50, 100, 150 (rpm) | SR | [14] |
Al6061 and Al6061-SiC drilling | Uncoated carbide Point angle: 96°, 118°, 140° Drill diameter: 10 mm | Feed rate: 0.1, 0.15, 0.2 (mm/rev) Cutting speed: 40, 60, 80 (rpm) | BH, BT | [25] |
Al6061-T6 turning | - | Feed rate: 0.2, 0.1, 0.05, 0.01 (mm/rev) Spindle speed: 1000 (rpm) | SR (rendering) | [35] |
2. Materials and Methods
2.1. Workpiece Material
2.2. Cutting Tools
2.3. Experimental Procedure
2.4. Measurement of Surface Roughness
2.5. Measurement of Hole Form and Dimensional Tolerances
2.6. Scanning Electron Microscopy
3. Results and Discussion
3.1. Analysis of Surface-Roughness Metrics
3.2. Effects of Cutting Parameters and Tool Coatings on Hole Size
3.3. Effects of Cutting Parameters and Tool Coatings on Circularity Error
3.4. Effect of Cutting Parameters and Tool Coatings on Hole Cylindricity and Perpendicularity
3.5. Cutting-Tool Examination
4. Conclusions
- The surface-roughness metrics Ra and Rz in most holes did not exceed 1 µm and 3 µm, respectively. Holes drilled using TiN-coated tools had the highest surface roughness. This was mainly attributed to the lower oxidation temperature and hardness of TiN coating and its high affinity to react with aluminum during the drilling process, as evident in the microscopic images.
- Hole size and circularity at the top were better than those at the bottom regardless of the tool coating or cutting parameters used. TiN/TiAlN-coated tools produced the worst hole size and circularity at the top, especially at low and medium spindle speeds, followed by holes drilled using TiN and TiAlN coatings.
- Under all cutting conditions, the holes produced were always oversized (between 15 and 80 µm). Similarly, hole circularity at the top and bottom ranged between 7 and 60 µm.
- TiN/TiAlN-coated tools produced the worst hole cylindricity, followed by the TiAlN and TiN tools. Hole cylindricity was the worst in TiN/TiAlN-coated tools, especially at low and medium spindle speeds. Holes drilled using TiN-coated tools gave the lowest hole cylindricity among the three coatings.
- TiN coatied tools were more suitable for drilling Al6061 alloy at low cutting parameters, while TiN/TiAlN- and TiAlN-coated tools were more suitable when machining at higher cutting parameters, where the thermal performance of the tool coating became more critical to the quality of machined holes.
- The ANOVA results showed that both the cutting parameters and the cutting-tool coatings had an impact on hole size, circularity, cylindricity, and perpendicularity. The contribution of the cutting-tool coating was more significant at the hole entry than at the exit. The spindle speed had a major effect on hole perpendicularity compared to feed rate and type of tool coating.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Properties | Metric | Element | Percentage |
---|---|---|---|
Density (g/cc) | 2.7 | Aluminum (Al) | 98 |
Ultimate Tensile Strength (MPa) | 310 | Chromium (Cr) | 0.04–0.35 |
Tensile Yield Strength (MPa) | 276 | Copper (Cu) | 0.15–0.4 |
Modulus of Elasticity (GPa) | 68.9 | Iron (Fe) | 0.7 |
Bearing Yield Strength (MPa) | 386 | Magnesium (Mg) | 0.8–1.2 |
Poisson’s Ratio | 0.33 | Manganese (Mn) | 0.15 |
Fatigue Strength (MPa) | 96.5 | Silicon (Si) | 0.4–0.8 |
Fracture Toughness (MPa-m½) | 29 | Titanium (Ti) | 0.15 |
Machinability (%) | 50 | Zinc (Zn) | 0.25 |
Shear Modulus (GPa) | 26 | ||
Specific Heat Capacity (J/g-°C) | 0.896 | ||
Melting Point (°C) | 582–652 | ||
Hardness (HV) | 107 |
Description | Tool A | Tool B | Tool C |
---|---|---|---|
Tool material | Solid carbide | Micrograin carbide | Solid carbide |
Drill diameter (mm) | 10 | 10 | 10 |
Helix angle (°) | 30 | 30 | 30 |
Point angle (°) | 140 | 140 | 140 |
Tolerance | M7 | M7 | M7 |
Coating | Firex coating (TiN/TiAlN) | TiAlN | TiN |
Flute length | 47 | 47 | 43 |
Overall length | 89 | 89 | 89 |
Color | Red violet | Black violet | Gold |
Coating thickness (μm) | 1.5–5 | 1.5–4 | 1.5–3 |
Layer structure | Multilayer | Monolayer | Monolayer |
Nano hardness (HV 0.05) | 3000–3300 | 3300 | 2400 |
Friction coefficient | 0.5 | 0.5–0.55 | 0.4–0.5 |
Oxidation resistance (°C) | 930 | 700–800 | 593 |
Manufacturer | GUHRING (Germany) | OSG (Japan) | GUHRING (Germany) |
Factor | Level 1 | Level 2 | Level 3 |
---|---|---|---|
Spindle speed (rpm) | 1000 | 2000 | 3000 |
Feed rate (mm/min) | 50 | 100 | 150 |
Coating | TiN/TiAlN | TiAlN | TiN |
Parameter | Ra | Rz | HST | HSB | HCT | HCB | HC | HP |
---|---|---|---|---|---|---|---|---|
Model | 50.79% | 50.48% | 91.91% | 86.34% | 64.50% | 60.94% | 73.62% | 97.00% |
Blocks | 0.34% | 0.42% | 0.32% | 1.80% | 0.70% | 1.27% | 0.83% | 0.09% |
Linear | 36.81% | 35.95% | 42.73% | 23.94% | 36.88% | 26.04% | 41.30% | 66.75% |
Spindle speed | 27.47% | 26.02% | 16.89% | 3.75% | 10.35% | 0.43% | 4.14% | 50.61% |
Feed rate | 4.11% | 4.88% | 1.95% | 3.39% | 4.06% | 6.08% | 2.75% | 1.68% |
Coating | 5.23% | 5.05% | 23.90% | 16.80% | 22.48% | 19.53% | 34.41% | 14.46% |
2-Way Interactions | 6.03% | 6.35% | 35.11% | 47.32% | 21.73% | 15.64% | 20.04% | 19.93% |
Spindle speed*Feed rate | 3.00% | 3.13% | 13.63% | 11.80% | 0.15% | 5.89% | 6.84% | 0.66% |
Spindle speed*Coating | 2.76% | 3.13% | 19.24% | 26.99% | 16.71% | 6.63% | 4.17% | 10.79% |
Feed rate*Coating | 0.27% | 0.09% | 2.24% | 8.52% | 4.87% | 3.11% | 9.04% | 8.48% |
3-Way Interactions | 7.61% | 7.76% | 13.74% | 13.27% | 5.19% | 18.00% | 11.45% | 10.23% |
Spindle speed*Feed rate*Coating | 7.61% | 7.76% | 13.74% | 13.27% | 5.19% | 18.00% | 11.45% | 10.23% |
Error | 49.21% | 49.52% | 8.09% | 13.66% | 35.50% | 39.06% | 26.38% | 3.00% |
Total | 100.00% | 100.00% | 100.00% | 100.00% | 100.00% | 100.00% | 100.00% | 100.00% |
Coating | Top (µm) | Bottom (µm) |
---|---|---|
TiN/TiAlN | 24.23–79.9 | 20.6–48.13 |
TiAlN | 17.83–34.87 | 19.87–29.17 |
TiN | 25.13–51.53 | 15.47–32.7 |
Coating | Top (µm) | Bottom (µm) |
---|---|---|
TiN/TiAlN | 18.33–59.63 | 7.03–15.13 |
TiAlN | 6.63–42.2 | 8.93–15.6 |
TiN | 12–26.4 | 9.3–19.7 |
Coating | Cylindricity (µm) | Perpendicularity (µm) |
---|---|---|
TiN/TiAlN | 33.27–78.10 | 53.23–76.03 |
TiAlN | 20.17–74.17 | 48–84.77 |
TiN | 22.77–44.67 | 66.57–84.83 |
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Al-Tameemi, H.A.; Al-Dulaimi, T.; Awe, M.O.; Sharma, S.; Pimenov, D.Y.; Koklu, U.; Giasin, K. Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy. Materials 2021, 14, 1783. https://doi.org/10.3390/ma14071783
Al-Tameemi HA, Al-Dulaimi T, Awe MO, Sharma S, Pimenov DY, Koklu U, Giasin K. Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy. Materials. 2021; 14(7):1783. https://doi.org/10.3390/ma14071783
Chicago/Turabian StyleAl-Tameemi, Hamza A., Thamir Al-Dulaimi, Michael Oluwatobiloba Awe, Shubham Sharma, Danil Yurievich Pimenov, Ugur Koklu, and Khaled Giasin. 2021. "Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy" Materials 14, no. 7: 1783. https://doi.org/10.3390/ma14071783