Volume 9 Issue 5
Sep.  2016
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OTIENO T, ABOU-El-HOSSEIN K. Effect of cutting parameters on tool wear in diamond turning of new optical aluminium grade[J]. Chinese Optics, 2016, 9(5): 579-587. doi: 10.3788/CO.20160905.0579
Citation: OTIENO T, ABOU-El-HOSSEIN K. Effect of cutting parameters on tool wear in diamond turning of new optical aluminium grade[J]. Chinese Optics, 2016, 9(5): 579-587. doi: 10.3788/CO.20160905.0579

Effect of cutting parameters on tool wear in diamond turning of new optical aluminium grade

doi: 10.3788/CO.20160905.0579
Funds:  Supported by the National Research Foundation, South Africa through the National Equipment Programme and the Technology Innovation Agency
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  • Author Bio:

    Timothy Otieno is a PhD Engineering student at the Nelson Mandela Metropolitan University. He received his BEng and MEng degree in Mechatronics from Nelson Mandela Metropolitan University in 2011 and 2012, respectively. His research focuses on the ultra-high precision machining of rapidly solidified aluminium alloys.E-mail:timothy.otieno@nmmu.ac.za

  • Corresponding author: E-mail:khaled.abou-el-hossein@nmmu.ac.za
  • Received Date: 21 Apr 2016
  • Rev Recd Date: 30 May 2016
  • Publish Date: 01 Oct 2016
  • Critical components in optical devices and optical measuring systems are mainly produced through the ultra-high precision machining. Aluminium alloys have been proven to be advantageous and very commonly used in the photonics industry. This ever-increasing use and demand in optics have led to the development of newly modified grades of aluminium alloys produced by rapid solidification in the foundry process. The newer grades are characterised by the finer microstructures and can improve mechanical and physical properties. Their main inconvenience currently lies in their having a very limited machining database as there is not enough adequate research contributions on their performance in terms of machinability when diamond turned. This paper investigates the machinability of rapidly solidified aluminium RSA 905 by varying diamond cutting parameters and measuring the diamond tool wear over a cutting distance of 4 km. The machining parameters varied were cutting speed, feed rate and depth of cut. The results show that the cutting speed is the most influential parameter on the diamond tool wear. The highest tool wear of 12.2 μm was achieved at the spindle speed of 500 rpm, the feed rate of 25 mm/min and the depth of cut of 15 μm. The lowest tool wear of 2.45 μm was recorded at the spindle of 1750 rpm speed, the feed rate of 5 mm/min and the depth of cut of 5 μm. Generally, a combination of higher cutting speeds, lower feed rates and smaller depths of cut caused less diamond tool wear. Statistical analysis was performed to develop a model for the diamond tool wear. Wear maps were generated from the model to identify zones where the cutting parameters produced the least wear. The results prove the rapidly solidified aluminium is a superior alternative to traditional aluminium alloys and can also provide a reference for machinists using this material.

     

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