The Research of Tool Wear Mechanism for High-Speed Milling ADC12 Aluminum Alloy Considering the Cutting Force Effect

Tool wear is a major cause of accelerated tool failure during the milling of aluminum alloy. The periodically cutting force directly affect the cutting heat and tool wear due to the intermittent cutting characteristics of the milling process. The focus of this paper is to analyze the influence of the variation of cutting force on tool wear behavior. The change law of cutting force by cutting parameters was analyzed firstly. Secondly, the variation of the wear land width (VB) of tool flank face by the milling length was analyzed. Thirdly, the wear morphology and the energy dispersive spectrometer (EDS) results of tool rake face and flank face in different cutting parameters were observed by tungsten filament scanning electron microscope. Finally, considering the cutting force effect, the tool wear mechanism during high-speed milling of Aluminum-Alloy Die Castings 12 (ADC12, 12 means aluminum number 12) was analyzed. The cutting force in tangential direction is predominant during high-speed milling aluminum alloy, which decreases gradually with the increase of cutting speed but increases gradually with the feed rising. The adhesion-oxidation wear was main wear mechanism of tool rake face during high-speed milling. While adhesive wear was the main wear mechanism of the tool flank face during high-speed milling. It is found that the formation of adhesive wear is the process from particle adhesion to melting until the formation of adhesive layer, which related to the change of cutting force.

Automated summary

This paper analyzed the influence of cutting force variation on tool wear behavior during the milling of aluminum alloy, focusing on the relationship between cutting parameters and tool wear, as well as the wear mechanism of tool flank face under different cutting parameters. The main findings suggest that the cutting force in tangential direction plays a predominant role during high-speed milling of aluminum alloy, with adhesion-oxidation wear being the primary mechanism on tool rake face and adhesive wear on tool flank face. Adhesive wear is related to the change of cutting force and occurs through a process from particle adhesion to melting to the formation of an adhesive layer.