Measurements of Forces and Temperature Fields in High-Speed Machining of 6061-T6 Aluminum Alloy |
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| Authors: | R V Kazban K M Vernaza Peña J J Mason |
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| Institution: | (1) Center for Nuclear Waste Regulatory Analyses, Southwest Research Institute, 6220 Culebra Rd., San Antonio, TX 78238, USA;(2) Mechanical Engineering, Gannon University, Erie, PA 16541, USA;(3) Department of Aerospace and Mechanical Engineering, 365 Fitzpatrick Hall of Engineering, University of Notre Dame, Notre Dame, IN 46556, USA |
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| Abstract: | This study focuses on experimental modeling of dry high-speed machining at 30 m/s cutting velocity using 6061-T6 aluminum
alloy. A modified Hopkinson bar apparatus is employed to simulate orthogonal machining, a focused array of mercury–cadmium–tellurium
infrared detectors is used to measure the temperature distribution around the tool tip, and a three-component quartz force
transducer is utilized in measuring the cutting and feed forces. The resulting measurements confirm the assumption of steady-state
cutting and allow for estimation of the partition of cutting work into heating, shear, and momentum changes in the chip. In
an earlier study, measurements of temperature distributions showed little heating of the finished surface. Therefore, a study
of the temperature fields generated during machining with a cutting tool that has a wear-land was performed. The wear-land
contributes significantly to the heating of the workpiece and, at this speed, is the most likely mechanism for the generation
of residual stresses and a temperature rise on the finished surface. |
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| Keywords: | Orthogonal machining High-speed machining Aluminum alloy Hopkinson bar Infrared temperature measurement Force measurement Energy Shear angle Friction coefficient Wear-land |
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