INVESTIGATING CUTTING FORCE AND CUTTING POWER WHEN TURNING AA6082-T4 ALLOY AT CUTTING DEPTHS SMALLER THAN TOOL NOSE RADIUS

Abstract

Aluminum alloys are widely preferred engineering materials in the manufacturing industry due to their high formability, good mechanical strength, and low density. Machining problems in aluminum alloys include built-up-edge formation, chip rupturing, and low surface quality, particularly in the 6xxx series due to the high Si content in the machining area. The aim of this study was to investigate the influence of cutting depth smaller than the tool corner radius, and various cutting parameters on cutting force and cutting power in machining AA6082-T4 alloy. In this context, the Johnson-Cook material model was established for AA6082-T4 alloy, and machining behaviors in terms of cutting force, and cutting power were investigated by performing finite element method (FEM) analyses using a full factorial design and variance analyses with different machining parameters. In conclusion, the lowest cutting forces were achieved with a cutting depth of 0.3 mm and a feed of 0.1 mm/rev, and the lowest cutting power was obtained with a cutting speed of 300 m/min, a cutting depth of 0.3 mm, and a feed of 0.1 mm/rev. In addition, the most effective machining parameters have been determined as cutting depth with a ratio of 91.74% for cutting force and cutting speed with a ratio of 33.13% for cutting power based on the results of variance and regression analysis.