Identification, Analysis and Evolution of the Mechanisms of Wear for Secondary Adhesion for Dry Turning Processes of Al-Cu Alloys

Abstract

In this work, Stereoscopic Optical Microscopy (SOM), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) have been applied for analyzing the evolution of tool wear during the dry turning process of aerospace Al-Cu alloys. The results derived from this analysis have revealed that secondary adhesion is the main tool wear mechanism that takes place in such process. So, in the first instants of the machining process, a Built-Up Layer (BUL) is developed onto the tool rake face by thermomechanical causes, promoting the conditions for developing a Built-Up Edge (BUE) which grows to a critical size. Starting from it, BUE is extruded giving rise to secondary BUL-BUE effects. When these are removed, tool particles are dragged out provoking the tool wear.