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Performance and wear mechanisms of uncoated, TiAlN, and AlTiN-coated carbide tools in high-speed drilling of Al-Si alloy

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Abstract

Owning to the extremely abrasive silicon particles, low melting point of aluminum, and its susceptibility to adhere to the tool, high-speed drilling of aluminum alloys containing high silicon content becomes a challenging operation. Hence, the understanding of the tool wear mechanisms is essential in order to develop and select the efficient tool material. This paper reports on the investigation of performance and wear mechanism of uncoated and TiAlN and AlTiN-coated tools when high-speed drilling of Al-Si (A383) alloy. Drilling tests were conducted at various cutting parameters, while thrust forces were measured using a dynamometer. The wear mechanisms that contributed to the drill failure were assessed by analyzing the worn cutting edge and drill bit cross section; and by employing scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). Results showed that feed rate has the highest effect on the primary wear stage; and flank wear at the outer cutting edge found to be dominant failure mode for all tools. Moreover, it is found that plastic deformation, diffusion, attrition, abrasion, and fracture are the main operating tool wear mechanisms. The longest tool life was recorded for AlTiN-coated tool, but more adhesion of Al was observed on this tool surface. At the end, TiAlN-coated drill was proposed as the tool with the best performance among the tool materials used in this study.

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Data availability

The data analyzed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors wish to thank the Manufacturing and Production Lab of Universiti Teknologi Malaysia (UTM) for their technical supports.

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Authors and Affiliations

  1. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia, 43500, Semenyih, Malaysia

    Ali Akhavan Farid

  2. School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81310, Johor Bahru, Johor, Malaysia

    Safian Sharif & Mohd Hasbullah Idris

Authors
  1. Ali Akhavan Farid
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  2. Safian Sharif
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  3. Mohd Hasbullah Idris
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Contributions

Ali Akhavan Farid: conceptualization, investigation, methodology, experiments, measurements, data analysis, validation, writing, and revising

Safian Sharif: supervision, conceptualization, reviewing, and editing

Mohd Hasbullah Idris: co-supervision and reviewing

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Correspondence to Ali Akhavan Farid.

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Akhavan Farid, A., Sharif, S. & Idris, M.H. Performance and wear mechanisms of uncoated, TiAlN, and AlTiN-coated carbide tools in high-speed drilling of Al-Si alloy. Int J Adv Manuf Technol 113, 2671–2684 (2021). https://doi.org/10.1007/s00170-021-06663-w

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