Effects of Cutting Condition on Surface Roughness when Turning Untreated and Sb-Treated Al-11%Si Alloys Using PVD Coated Tools

Abstract

Surface roughness is an important output in different manufacturing processes. Its characteristic affects directly the performance of mechanical components and the fabrication cost. In this current work, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness in turning the untreated and Sb-treated Al-11%Si alloys. Experimental trials carried out using PVD TIN coated inserts. Experiments accomplished under oblique dry cutting when three different cutting speeds have been used at 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut kept constant at 0.05 mm. The results showed that Sb-treated Al-11%Si alloys have poor surface roughness in comparison to untreated Al-11%Si alloy. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.