Abstract
A series of orthogonal cutting tests of aluminum alloys have been carried out
using four non coated and four coated cutting tools to investigate the chip formation process and adhesion of the work material to the rake face of the cutting tool under near dry cutting conditions.
Almost no adhesion of the work material was observed over a wide range of tested cutting speeds when the aluminum alloy was cut with a sintered diamond cutting tool. On the other hand, large amount of work material adhesion was observed at low cutting speeds when cutting was performed with cemented carbide, DLCcoated, TiNcoated, and TiAlN coated tools. The amount of the adhered material decreased as the cutting speed increased. When cutting was performed with a single crystal diamond tool, no adhesion of the work material was observed on the rake face of the tool even at low cutting speeds. However, aluminum adhered on the rake face of the tool when cutting was performed wit h a CVD diamond coated or CBN tools at low cutting speeds.
When the nominal coefficient of friction on the rake face obtained by measuring cutting force components was 0.5 or more, adhesion formed and splits were observed in the cross section of the chips at the contact surface wit h the tool. The chemical components of the adhered layer were also analyzed by EDS (Energy Dispersive Spectrometer), XPS (X ray photoelectron spectroscopy), and AES (Auger Electron Spectrometer) techniques.
Keywords - near dry cutting, aluminum alloys, adhesion, coefficient of friction, tool materials