Skip to main content
Log in

An experiment study of hard coating and cutting fluid effect in milling aluminum alloy

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper investigates the cutting performance of a tungsten carbide end mill with hard coating and a sulfurous boric acid ester cutting fluid in milling A6061P-T651 aluminum alloy. The experiments were conducted to compare the milling force responses and flank wear under various cutting conditions. The results indicate that adding sulfurous boric acid ester cutting fluid decreases tool wear by 12.5% for hard coating tungsten carbide end mills and decreases the milling force by 10%. Besides, the average values of side and end flank wear of TiAlN-surface multilayer end mills can be decreased 38.7% and 68.7% respectively compared with uncoated and dry end mills.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. Baradie MAE (1996) Cutting fluids: part II- recycling and clean machining. J Mater Process Technol 56:798–806

    Article  Google Scholar 

  2. Nedelik J, Lux B (1999) Improved tool performance by application of heat-spreading diamond layers within a multilayer coating? Int J Refract Met Hard Mater 17:275– 282

    Article  Google Scholar 

  3. Chen CS (1998) High speed and high performance milling aluminum alloy in aerospace industry. Machinery Monthly 276:293–296 (in Chinese)

    Google Scholar 

  4. Machado AR, Wallbank J (1997) The effect of extremely low lubricant volumes in machining. Wear 210:76–82

    Article  Google Scholar 

  5. Kelly JF, Cotterell MG (2002) Minimal lubrication machining of aluminum alloys. J Mater Process Technol 120:327–334

    Article  Google Scholar 

  6. Varadarajan AS, Philip PK, Ramamoorthy B (2002) Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning. Int J Mach Tools Manuf 42(2):193–200

    Article  Google Scholar 

  7. Cozzens, DA, Rao PD, Olson WW, Sutherland JW, Panetta JM (1999) An experimental investigation into the effect of cutting fluid conditions on the boring of aluminum alloys. ASME J Manuf Sci Eng 121(3):434–439

    Google Scholar 

  8. Kress D (1997) Dry cutting with finish machining tools. Ind Diamond Rev 57(574):81–85

    Google Scholar 

  9. Chia XM, Chang HL (1996) The effect of compound boric acid ester additives in water-based fluids. Mach Manuf 12:23–24 (in Chinese)

    Google Scholar 

  10. Mould RW, Silver HB, Syrett RJ (1977) Investigation of the activity of cutting oil additives part V - The EP activity of some water-based fluids. Lubr Eng 33(6):291–298

    Google Scholar 

  11. Jain VK, Shukla DS (1996) Study of the EP activity of water-soluble inorganic metallic salts for aqueous cutting fluids. Wear 193(1):226–234

    Article  Google Scholar 

  12. Baradie MAE (1996) Cutting fluids: part I - characterization. J Mater Process Technol 56:786–797

    Article  Google Scholar 

  13. Astakhov VP, Osman MOM (1996) Correlations amongst process parameters in metal cutting and their use for establishing the optimum cutting speed. J Mater Process Technol 62:175–179

    Article  Google Scholar 

  14. Hung NP, Yeo SH, Oon BE (1997) Effect of cutting fluid on the machinability of metal matrix composites. J Mater Process Technol 67:157–161

    Article  Google Scholar 

  15. Haan DM, Batzer SA, Olson WW, Sutherland JW (1997) An experimental study of cutting fluid effects in drilling. J Mater Process Technol 71:305–313

    Article  Google Scholar 

  16. Mould RW, Silver HB, Syrett RJ (1972) Investigation of the activity of cutting oil additives part I- organo sulfur containing compounds. Wear 19(1):67–80

    Article  Google Scholar 

  17. Mould RW, Silver HB, Syrett RJ (1972) Investigation of the activity of cutting oil additives part II- organo chlorine containing compounds. Wear 22(2):269–286

    Article  Google Scholar 

  18. Shah MC (1958/59) On the action of metal cutting fluids at low speeds. Wear 2:217–227

    Article  Google Scholar 

  19. Brown WL (1998) The role of polyalkylene glycols in synthetic metal working fluids. Lubr Eng 44(2):168–171

    Google Scholar 

  20. Tsao CC (2000) Study on tool life and surface roughness in milling aluminum alloys using sulfurous boric acid ester cutting fluids by Taguchi method. in: Proceedings of the 17th Conference CSME 4:425–428 (in Chinese)

  21. Hedenqvist P, Olesson M, Wallen P, Kassman A, Hogmark S, Jacobson S (1990) How TiN coatings improve the performance of high speed steel cutting tools. Surf Coat Technol 41(2):243–256

    Article  Google Scholar 

  22. Drozda TJ, Wick C (1983) Tool and manufacturing engineers handbook Vol. 1 - machining, 4th edn. SME, Dearborn, MI

    Google Scholar 

  23. Gunther KG, Freller H, Hintermann HE, Konig W (1989) Advanced coatings by vapour phase processes. Ann CIRP 38(2):645–655

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to C. C. Tsao.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Tsao, C.C. An experiment study of hard coating and cutting fluid effect in milling aluminum alloy. Int J Adv Manuf Technol 32, 885–891 (2007). https://doi.org/10.1007/s00170-006-0417-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-006-0417-6

Keywords

Navigation