Effect of High Speed Machining on the Turning Aluminum Alloy 6061

of the Integrity Coated TiAlN/TiN Cutting Tool Carbide

Sunarto and Razali

Department of Mechanical Engineering, Politeknik Negeri Bengkalis, Jalan Bathin Alam, Bengkalis, Indonesia

Keywords: Cutting Speed (Vc), Cutting Tools, Coating Materials, Titanium.

Abstract: Improved performance of carbide cutting tools that are widely used in the field of the metal cutting machining

process is done by coating the base material of the cutting tool with the coating material. From the results of

previous research, it was concluded that cutting tools coated with Titanium Aluminum Nitride and Titanium

Nitride (TiAlN/TiN) have toughness when cutting stainless steel. Other studies have concluded that coating

materials do not work properly when used to cut nonferrous metal alloys (Titanium). The integrity of the

coating element is very closely related to the mechanism of cutting tool wear in the form of chemical reactions.

The response between TiAlN/TiN coating material and the cut base material of Aluminum alloy 6061 became

the subject to be observed in this study. The cutting method is divided into three categories, namely low with

cutting speed Vc 800 m/min, medium with cutting speed Vc 1000 m/min, and high with cutting speed of 1200

m/min. The results of the study concluded that each cutting condition specified for each TiAlN/TiN coating

element observation point has not been found.

1 INTRODUCTION

Cutting speed above ≥ 1000 m/min for cutting

aluminum alloy material type is categorized in high

speed machining (Schulz & Moriwaki, 1992). The

impact arising from high cutting speed is the

increasing cutting temperature (Schey, 2000)

(Abhang, L.B., et al, 2010) (Nouari, et al, 2003).

According to Rochim (1993), the result of oxidation

at high cutting speeds resulted in decreased cutting

tool carbide resistance. Efforts are made to improve

the toughness of cutting tool carbide (WC+Co) by

coating the base material of the cutting tool using

coating materials including Titanium Aluminum

Nitride (TiAlN) and Titanium Nitride (TiN). It is

expected that the coating can serve as a solid lubricant

and as a sealing wall between the base material of the

cutting tool against the workpiece, thus the rate of

damage to the cutting tool can be suppressed.

According to Yin Fei, et al, (2005) multilayer layers

made on layered cutting tool carbide (TiAlN/TiN)

have high hardness, are wear-resistant, more resilient

in cutting when compared to coatings made of

monolayers (TiAlN), this study was conducted on the

lathe using stainless steel material with a cutting speed

(Vc) of 220 m/min, feeding motion (f) 0.2 mm

/round and cutting depth (a) 0.2 mm. The performance

of the Titanium Nitride (TiN) coating found in the cutting.

tool is not by its function when cutting the Alloy

Titanium Ti-6246 at a cutting speed milling operation

(Vc) of 55 m/min, feeding motion (f) 0.1 mm/tooth and

feeding depth (a) 2 mm were found to have an exfoliating

coating at the beginning of the initial wear process and

were concluded as a result of high reactivity to Titanium

Ti-6246 during the cutting process (S.Sharif, et al. 2008).

Other findings relating to the exfoliation of coatings

against cutting tool base materials at the beginning of

cutting were also presented by G.A. Ibrahim, et al, (2010)

on Titanium alloy material with lathe operation with

cutting speed (Vc) off 55 m/min, feeding motion (f) 0.15

mm/round and cut depth (a) 0.10 mm.

To see the integrity of coating materials in this

study the authors will conduct experiments that are

cutting Aluminum alloy 6061 using layered cutting

tool carbide of Titanium Aluminum Nitride and

Titanium Nitride (TiAlN/TiN) at cutting speeds of

800, 1000, and 1200 m/min in cutting conditions

without the use of coolant.

1.1 High-speed Machining

High-Speed Machining is one of today's modern

technologies, where in comparison with conventional

Sunarto, . and Razali, .

Effect of High Speed Machining on the Turning Aluminum Alloy 6061 of the Integrity Coated TiAlN/TiN Cutting Tool Carbide.

DOI: 10.5220/0010946900003260

In Proceedings of the 4th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2021), pages 423-428

ISBN: 978-989-758-615-6; ISSN: 2975-8246

 2023 by SCITEPRESS – Science and Technology Publications, Lda. Under CC license (CC BY-NC-ND 4.0)

423

cutting processes it is possible to improve the

efficiency, accuracy, and quality of the workpiece and

at the same time can lower the costs and machining

times. Schulz (1992) says that the process of high-

speed machining is determined based on the type of

material used as shown in Figure 1.

Figure 1: Cutting Speed at High-Speed Processes.

1.2 Cutting Temperature

Because the cutting area continues to move on the

workpiece, the heating rate in front of the cutting tool

is relatively small, and at least at high cutting speeds,

most of the heat (more than 80%) is carried away by

the chip. Nevertheless, the cutting tool continuously

intersects with the chip since there is no heat sealing

layer, the side face of the cutting tool becomes hot.

Friction on the face of the cut side (deformation in the

cutting area of the secondary) is also the cause of

heating. Detailed calculation results show that the

maximum temperature occurs on the face of the cut

side which is located a bit far from the end of the

cutting tool before the chip is lifted. As expected, the

maximum temperature (Tmax) and average interface

temperature (Tint) rise as the cutting speed increases,

as shown in Figure 2.

Figure 2: (a) Calculation of temperature distribution in chip

and cutting tools, (b) Temperature variation with cutting

speed during AISI 1016 steel cutting with carbide cut

chisel.

According to Abhang L.B et al, (2010) in their

research on the lathe process using alloy steel

workpieces with EN-31 series temperature increase in

cutting tool is the effect of cutting conditions. More

clearly they elaborate as follows:

1. Result of cutting speed (Vc) The cutting speed

greatly affects the increase in cutting

temperature. They further explained that the

increasing speed of friction cutting will

increase, which will lead to an increase in

temperature in the cutting zone.

2. As a result of the motion of eating (f) With

increased feeding motion (f) affecting the

growl, causing increased friction and causing

a rise in cutting temperatures, this is as

reported by Shaw (1984), Stephenson (1992).

3. Resulting from cutting depth (a) Changes in

cutting temperature are recorded in the cutting

zone as a function of cutting depth for different

cutting speeds and feeding motions with a

constant cutting tool radius (0.4mm).

1.3 Mecanishm Cutting Tool Wear

One of the mechanisms of cutting tool wear is a

chemical reaction. Two surfaces that rub against each

other with considerable pressure along with an active

chemical environment (air or coolant with a certain

composition) can cause interaction between the

cutting tool material and the workpiece. The newly

formed workpiece material surface (the sultry surface

and the cut workpiece surface) are so chemically

active that it is easy to react again and stick to the

cutting tool surface. At low cutting speeds, oxygen in

the air in the gaps between the cutting tool with a

growl or workpiece has the opportunity to react with

the material of the workpiece to reduce the degree of

unification with the surface of the cutting tool. As a

result, the contact area where the shift between the

cutting tool and the chip/workpiece will be wider so

that the wear and tear process due to friction will

occur faster. To observe damage/wear of the cutting

tool coating as a result of chemical reactions used

Microscope Elekron Scanning and Energy Dispersive

X-Ray Spectroscopy (SEM-EDS). SEM- EDS is a

tool that can provide direct information about the

topography (texture of the sample surface),

morphology (shape and size), composition

(constituent elements of the sample), as well as

crystallography information (atomic arrangement of

the sample preparation).

Ginting (2006) damage to the coating element in

the form of coating delamination is the occurrence of

loss of cutting tool in the form of layers from

surface of the cutting tool. The exfoliation of the

coating can be seen in Figure 3.

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Figure 3: Coating Delamination Cutting Tool.

According to Nouari and Ginting (2006), in the case

of cutting tool coated exfoliation occurs with the

beginning of micro-cracks that take place inside the

coating layer and then followed by the rapid removal

of the layer material. In general, the investigation of

coating peeling is not an easy job, it is due to the

complex interaction between several factors that play

a role in exfoliation such as Dry Machining Operation

Environment (DMOE), the nature of coating

materials, and the interaction between cutting tool,

layers, and workpieces.

2 RESEARCH METHOD

Research on the effect of high cutting speed on the

turning of aluminum 6061 on the integrity of cutting

tool carbide coated TiAlN/TiN material was

conducted experimentally. Observing the integrity of

the coating material is done by dividing it into three

cutting conditions, namely low, medium and high

cutting conditions.

Data retrieval under low category cutting

conditions is carried out with the following

steps:

Cutting Aluminum alloy 6061 with cutting

speed (Vc) of 800 m/min, feeding motion (f)

0.2 mm/round, cutting depth (a) 1.5 mm,

and cutting time length (tc) more than 6

minutes (ISO 3685, 1977).

The integrity of coating materials is

detected using Energy Dispersive X-Ray

Spectroscopy (EDS).

Data retrieval in category medium conditions is

being done with the following steps:

Cutting Aluminum alloy 6061 with cutting

speed (Vc) of 1000 m/min, feeding motion

(f) 0.2 mm/round, cutting depth (a) 1.5 mm,

and cutting time (tc) more than 6 minutes

(ISO 3685, 1977).

The integrity of coating materials is

detected using Energy Dispersive X-Ray

Spectroscopy (EDS).

Data retrieval under high category cutting

conditions is carried out with the following

steps:

Cutting Aluminum alloy 6061 with cutting

speed (Vc) of 1200 m/min, feeding motion

(f) 0.2 mm/round, cutting depth (a) 1.5

mm, and cutting time (tc) longer than 6

minutes (ISO 3685, 1977).

The integrity of coating materials is

detected using Energy Dispersive X-Ray

Spectroscopy (EDS).

3 RESULT AND DISCUSION

3.1 Low Category Cutting

Detection results using Energy Dispersive X-Ray

Spectroscopy (EDS) after cutting Aluminum alloy

6061 in the low category at the 7 spectrum

observation point were not found elements of

TiAlN/TiN coating material and the discovery of

Tungsten element (W) by 52.20% and Cobalt

element (Co) by 3.92%. Tungsten (W) and Cobalt

(Co) are the basic ingredients of cutting tools carbide

(WC+Co). An aluminum element of 14.54% is

indicated as a chip of a cut workpiece attached to the

surface of the cutting tool. Meanwhile, at the

observation point of spectrum 6 also not found

elements of TiAlN/TiN coating material and the

discovery of tungsten element (W) of 60.72 % and

cobalt element (Co) of 4.06% more than at the

observation point of spectrum 7.

Based on the above EDS results can be said that

at the speed of cutting speed 800 m/min coating

material elements namely Titanium Aluminum

Nitride (TiAlN) and Titanium Nitride (TiN) has not

been found. The EDS results can be seen more clearly

in Figure 4 and Figure 5:

Effect of High Speed Machining on the Turning Aluminum Alloy 6061 of the Integrity Coated TiAlN/TiN Cutting Tool Carbide

425

Figure 4: Observation Points on Spectrum 7.

Figure 5: Observation Points on Spectrum 6.

3.2 Medium Category Cutting

Detection results using Energy Dispersive X-Ray

Spectroscopy (EDS) after cutting Aluminum alloy

6061 in the medium category at the observation point

of spectrum 1 were not found elements of TiAlN/TiN

coating material and the discovery of Tungsten

element (W) by 82.85% and Cobalt element (Co) by

4.29%. On the spectrum of 4 EDS results were also not

found elements of coating materials (TiAlN/TiN) and

the discovery of tungsten element (W) by 79.09% and

Cobalt element (Co) by 3.87%. Detection results at

cutting speeds of 1000 m/min greater Tungsten

element (W) and Cobalt (Co) element were found

when compared to cutting speeds of 800 m/min. It

can be said that at a cutting speed of 1000 m/min the

TiAlN/TiN coating material element disappears

faster when compared to the cutting speed of 800

m/min. The EDS results can be seen more clearly in

Figure 6 and Figure 7:

Figure 6: Observation Points on Spectrum 1.

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Figure 7: Observation Points on Spectrum 4.

3.3 High Category Cutting

Detection results on the spectrum 8 is dominated by

the basic elements of the cutting tool cobalt (Co) 5.55

% and Wolfram (W) 64.01 %. No Titanium

Aluminum Nitride (TiAlN) and Titanium Nitride

(TiN) were found to have been lost in 6 minutes

cutting time at a cutting speed of 1200 m/min.

Observation points on the spectrum 4 were also found

the basic elements of the chisel cobalt (Co) 4.91% and

Tungsten (W) 64.01%. Found aluminum element (Al)

by 8.84% is estimated to be a chip attached to the

surface of the chisel. The EDS results can be seen

more clearly in Figure 8 and Figure 9:

Figure 8: Observation Points on Spectrum 8.

Figure 9: Observation Points on Spectrum 4.

Effect of High Speed Machining on the Turning Aluminum Alloy 6061 of the Integrity Coated TiAlN/TiN Cutting Tool Carbide

427

4 CONCLUSION

The result of cutting Aluminum alloy 6061 at high

cutting speed in the turning process can be concluded

as follows:

1. At the cutting speed of the low category,

namely 800 m/min at observation points 6 and

7, no TiAlN/TiN coating material was found,

the average element of Wolfram (W) was

56.46% and Cobalt (Co) was 3.99 % which is

the base material for cutting tool.

2. At the cutting speed of the medium category,

namely 1000 m/min, observation points 1 and

4 did not find TiAlN/TiN coating material

elements, the average Wolfram element was

80.97% and Cobalt was 8.16%. The basic

elements in the form of Wolfram and Cobalt

were found more than at a cutting speed of

800 m/min.

3. At the cutting speed of the high category,

namely 1200 m/min, observation points 8 and

4, TiAlN/TiN coating materials were not

found, Wolfram elements were found on

average 64% and Cobalt was 5.23%. In the

three low, medium and high cutting

conditions at several observation points the

presence/integrity of TiAlN and TiN as

cutting tool coating materials was not found.

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