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Metalworking Fluid Performance in Discontinuous Cutting of an Aluminum Alloy

Company: Quaker Houghton

Major(s):
Primary: IE
Secondary: ME

Non-Disclosure Agreement: YES

Intellectual Property: YES

Metalworking Fluid Performance in Discontinuous Cutting of an Aluminum Alloy Background The machining performed in the manufacture of aluminum wheels includes hole making operations, rough and finish turning as well as final polishing steps done to give the wheel surface a bright and shiny appearance. The finish turning operation is an important operation in that the roughness and appearance of the turned surface largely influences the surface quality and appearance of the final wheel. This proposed project aims to study the effects of machining conditions as well as metalworking fluid performance in the finish turning of Aluminum alloys, which are widely used in wheel production. Using a turning operation on the outer diameter of aluminum cylinders, with notches on the OD to help simulate the discontinuous cutting that takes place during aluminum wheel machining, the effects of metalworking fluid performance will be studied regarding machined surface roughness and appearance, insert wear, burr formation, and the level of aluminum welded or transferred to the cutting insert. Deliverables: 1. Using a horizontal machining center, complete single point finishing operation on Al cylinders with notches while using cutting conditions and tooling consistent with those utilized in industrial Al wheel machining operations. 2. Conduct testing of three different metalworking fluids in the OD turning of the Al alloy fluid performance via measurement of machined surface roughness, appearance and texture, as well as by measurement of the tool wear, metal (Al) build-up formed on the cutting insert and a strong emphasis on burr formation during the machining operation.