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Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

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Abstract

Micro-texturing has been widely proven to be an effective technology for achieving sustainable machining. However, the performance of micro-textured tools under different cooling conditions, especially their coupling effect on machined surface integrity, was scarcely reported. In this paper, the non-textured, linear micro-grooved, and curvilinear micro-grooved inserts were used to turn aluminum alloy 6061 under dry, emulsion, and liquid nitrogen cryogenic cooling conditions. The coupling effects of different micro-textures and cooling conditions on cutting force, cutting temperature, and machined surface integrity, including the surface roughness, work hardening, and residual stress, were revealed and discussed in detail. Results indicated that the micro-grooved tools, especially the curvilinear micro-grooved tools, not only reduced the cutting force and cutting temperature, but also improved the machined surface integrity. In addition, the micro-grooved tools can cooperate with the emulsion or liquid nitrogen to reduce the cutting force, cutting temperature, and improve the machined surface integrity generally, although the combination of emulsion cooling condition and micro-grooved tools generated negative coupling effects on cutting forces and surface work hardening. Especially, the combination of curvilinear micro-grooved cutting tools and cryogenic cooling condition resulted in the lowest cutting force and cutting temperature, which generated the surface with low roughness, weak work hardening, and compressive residual stress.

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Acknowledgements

This work is financially supported by the National Natural Science Foundation of China (Grant Nos. 52005281, 52005215 and 52074161), the Natural Science Foundation of Shandong Province (Grant No. ZR2020QE181), and the Open Research Fund of State Key Laboratory of High Performance Complex Manufacturing, Central South University (Grant No. Kfkt2020-06).

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Authors and Affiliations

  1. Key Lab of Industrial Fluid Energy Conservation and Pollution Control, Ministry of Education; School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266520, Shandong, People’s Republic of China

    Guo-Liang Liu, Jin-Tao Zheng, Shu-Feng Sun, Xin-Fu Liu & De-Xiang Wang

  2. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha, 410083, People’s Republic of China

    Guo-Liang Liu

  3. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture (Ministry of Education), School of Mechanical Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Guo-Liang Liu

  4. School of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, People’s Republic of China

    Chuan-Zhen Huang

  5. Qingdao Choho Ind Co Ltd, Qingdao, 266705, Shandong, People’s Republic of China

    Long-Jie Dai

  6. School of Mechanical Engineering, University of Jinan, Jinan, 250022, People’s Republic of China

    Xiang-Yu Wang

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  1. Guo-Liang Liu
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Liu, GL., Zheng, JT., Huang, CZ. et al. Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061. Adv. Manuf. 11, 663–681 (2023). https://doi.org/10.1007/s40436-022-00432-y

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  • DOI: https://doi.org/10.1007/s40436-022-00432-y

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