Experimental Study of Cutting Performance and Tool Wear in Dry Side Milling of Aluminum Alloy with DLC-Coated HSS-Co Cutter
This paper presents the experimental results of cutting performance and tool wear of a milling cutter in dry side milling of aluminum alloy A2017. The milling cutter consists of Co-bonded High-Speed-Steel matrix with Diamond-Like-Carbon coating (abbrev. DLC-coated HSS-Co cutter). The machining experiments were carried out under cutting speed of 63 to 189 [m•min-1] and feed of 0.08 [mm/tooth/rev], and the criterion of tool life was the generation of gauge and/or scratch on a machined surface. The experimental results support that the DLC-coated cutter in up cutting has good performance among four types of combination by the presence or absence of coating and the up/down cutting manner. They also showed that the tool life of DLC-coated cutter in up cutting under cutting speed of 157 [m•min-1] was corresponding to the cutting distance of 80 [m] with average width of flank wear 102 [μm] and that in down cutting was 60 [m] with 85 [μm]. In the range of cutting distance up to 100 [m], the resultant cutting force with the DLC-coated cutter was smaller than that with a non-coating cutter. In case of the DLC-coated cutter in up cutting under the cutting speed of 189 [m•min-1], a chatter vibration occurred during the initial cutting distance. In case of the radial depth of cut of 1.5 [mm], it lasted up to the cutting distance of 10 [m] and more.
Tojiro Aoyama, Hideki Aoyama, Atsushi Matsubara, Hayato Yoshioka and Libo Zhou
Y. Mizugaki et al., "Experimental Study of Cutting Performance and Tool Wear in Dry Side Milling of Aluminum Alloy with DLC-Coated HSS-Co Cutter", Key Engineering Materials, Vols. 523-524, pp. 64-69, 2012