The performance of advanced cutting tools used for dry machining of aluminium

This study aims to evaluate the performance of different cutting tools and their influence on the machining process of rolled aluminium. Eight different inserts, including five multilayer (C and S-type), two single-coated, and one uncoated SPUN cemented carbide inserts, were compared to determine the best machinability criteria for aluminium. The comparison included evaluating different cutting speeds and feed intervals while maintaining the same depth of cut. The chip morphology study showed that the C-type insert (MTCVD-TiN-TiCN-Al2O3-TiN) exhibited the largest chip curl radius and negatively affected the workpiece. The S-type (MTCVD-TiN-TiCN-Al2O3-TiN) insert showed no built-up edge formation (BUE) in the rake face, as seen in a field-emission scanning electron microscope (FESEM). Advanced PVD-coated AlTiN inserts and C-type inserts (MTCVD-TiCN-Al2O3) showed minimal wear on the primary and secondary flanks, respectively. The multicoated S-type tool (MTCVD-TiCN-Al2O3-TiOCN) showed the lowest primary and secondary flank wear. Furthermore, PCD brazed carbide tools exhibited minimal cutting force value at both feed rates. Uncoated carbide inserts were more wear-resistant than other multicoated tools. The ANOVA analysis identified the significant parameters affecting cutting force, surface roughness, and chip reduction coefficient, referred to as response variables in the study. The multicoated C-type tools (MTCVD-TiCN-Al2O3-TiOCN) showed optimal performance according to the results of the Taguchi-Grey relation analysis. This tool demonstrated a lower chip reduction coefficient and a better workpiece surface finish at an increased feed rate. These findings emphasize the effectiveness of these tools when working with ductile materials like aluminium.