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Chip morphology study in high speed drilling of Al–Si alloy

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Abstract

Chip formation during drilling operation is greatly influenced by the cutting parameters such as cutting speed, feed rate, and drill geometry. However, not many studies have focused on the direct observation of the chip formation during high speed drilling. This paper investigates the effect of cutting speed and feed rate on the chip morphology during high speed drilling of aluminum–silicon alloys using carbide drill. Observation on the multiview characterization of the chips was carried out which includes free surface, back surface, and cross-section of top surface. Structure and shape alterations of the free and back surfaces were analyzed using a scanning electron microscope. Finally, different geometrical parameters of chip cross-section were measured in order to study the effect of cutting parameters on chip compression ratio and thrust force. It was found that increase in cutting speed significantly affects the chip morphology especially on the structure of free surface and cross-section of the chips. Results also showed that built-up edge on the rake face of tool played an important role on the formation of irregular pattern on the chip back surface.

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Authors and Affiliations

  1. Department of Manufacturing and Industrial Engineering, Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, Skudai, 81310, Johor, Malaysia

    Ali Akhavan Farid, Safian Sharif & Mohd Hasbullah Idris

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  1. Ali Akhavan Farid
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  2. Safian Sharif
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  3. Mohd Hasbullah Idris
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Correspondence to Safian Sharif.

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Akhavan Farid, A., Sharif, S. & Idris, M.H. Chip morphology study in high speed drilling of Al–Si alloy. Int J Adv Manuf Technol 57, 555–564 (2011). https://doi.org/10.1007/s00170-011-3325-3

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  • DOI: https://doi.org/10.1007/s00170-011-3325-3

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