Affiliation:
1. Michigan Technological University
2. Ford Research and Advanced Engineering
Abstract
This two-part paper is directed at the development of a machining force model that addresses key microstructural features of 319 Aluminum. In Part 1 of this paper, a machining force model is presented that incorporates microstructural effects. Secondary Dendrite Arm Spacing (SDAS) is identified as a significant microstructure feature of 319 aluminum in terms of machinability, and the SDAS is related to the solidification rate. A new material constitutive relationship that incorporates SDAS microstructure effects is proposed. In Part 2 of this paper, the results from material tests and machining experiments are presented. A new methodology for estimating parameters within the material constitutive model is described, and force model predictions are compared with the results from machining tests. The comparison reveals an excellent agreement between measured and predicted forces.
Reference33 articles.
1. Hatch, D. E., and Jorstad, J. L., 1978, “Aluminum Structural Castings Result in Automobile Weight Reduction,” SAE Technical Paper No. 780248.
2. Yasunori, K., Takeo, A., Haruki, A., Masakazu, S., and Yasushi, N., 1991, “Application of Aluminum for Automobile Chassis Parts,” SAE Technical Paper No. 910554.
3. Yamada
H.
, and TanakaT., 1976, “Effect of Cast Structure on the Machinability of Aluminum alloys,” Journal of Japan Institute of Light Metals, 26, (11), pp. 550–557.
4. Jorstad, J. L., 1980, “Influence of Aluminum Casting Alloy Metallurgical Factors on Machinability,” SAE Technical Paper No. 800486.
5. Batzer
S.
, HaanD., RaoP., OlsonW., and SutherlandJ. W., 1998, “Chip Morphology and Hole Surface Texture in the Drilling of Cast Aluminum Alloys,” J. of Matls. Processing Tech., 79/1–3, pp. 72–78.