Flank wear and cutting temperature in half-immersion up-milling of 6061 Aluminium Alloy

Abstract

Research findings indicate that flank wear is closely related to cutting temperature, but the relationship of varying cutting distance on flank wear and cutting temperature is rarely defined, as well as determining the ideal cutting distance. Dry machining provides rhythm as the manufacturing industry profits from cutting fluid drawback. However, with the absence of this fluid, it will lead to catastrophic flank wear and cutting temperature especially on long cutting distance. This manuscript presents the comparative assessment of flank wear and cutting temperature under dry and wet condition, when varying the cutting distance in half-immersion up-milling of 6061 Aluminium Alloy. The results show that flank wear and cutting temperature are directly proportional to cutting distance under both conditions. Dry condition is the ideal approach as compared to wet condition when half-immersion up-milling is performed at cutting distance up to 270 mm, while wet condition is the ideal approach as compared to dry condition when the cutting distance is beyond 270 mm.