A machining performance study in dry contour turning of aluminum alloys with flat-faced and grooved diamond tools

This paper presents the results from an experimental study of dry contour t urning operations on aluminum alloys (6061B and 2011-T3) using PCD flat-fac ed and diamond coated grooved tools. The machining performance is assessed on the basis of cutting forces, chip flow, chip-form and surface roughness observed during contour turning operations. The constantly varying cutting conditions (especially effective depth of cut due to varying geometry of th e contour surface) and effective tool geometry cause a wide fluctuation in cutting forces and the ensuing chip flow. The chip flow angle is measured a long the contour geometry using high-speed filming techniques and these res ults are compared with predicted chip flow values from the measured experim ental cutting forces (which are measured along the entire contour geometry) . The resultant surface roughness at different locations along the contour profile is measured and correlated with the chip flow and chip-form variati ons. Machining performance issues specifically relevant to dry contour turn ing of aluminum (such as problems due to poor chip flow and the resultant p oor surface roughness) are studied and the effectiveness of selective work- tool (both tool material and tool geometry) pairs is illustrated.