Effect of Si on Machinability of Al-Si-Mg Alloy and Evaluation of Tool Life with the Application of Biodegradable Esterified Nano Cutting Fluid

An investigation was conducted to evaluate the effect of Si content on the machinability of Al-Si-Mg alloy. The effect of biodegradable nano esterified cutting fluid on the machinability and surface finish of the alloy and the tool wear was evaluated. Al-Si-Mg alloys with varying Si content (4-12 % wt) was used for the investigation. The way the microstructure and the mechanical properties change depending on the increase in the %Si amount in the alloy and the effects of such changes on Flank Build-up (FBU), wear in the cutting edge, surface roughness, and machinability were analysed. With the increase in the %Si amount machinability of the alloy improved providing a smooth surface and cutting force gradually decreased. Again with the addition of biodegradable nano esterified cutting fluid surface roughness and tool wear were also found to decrease. Light cut was employed and the cutting speeds used were 60 m/min,80m/min and 100m/min and the feed rates 0.2 mm/rev, 0.3 mm/rev and 0.4 mm/rev with depth of cut 0.5 mm, 0.1 mm and 1.5 mm respectively. Lathe Tool Dynamometer, Model: VT-TDM11 was used to measure the cutting force. Mitutoyo Surface roughness tester was used to measure the surface roughness of the machined samples.