Investigation on Effect of AlCrN & DLC Coated Carbide Tool in Machining of LM6 Aluminum Alloy

Abstract

Aluminum and its alloys are abundantly available in nature. Since its properties like High strength to weight ratio, Corrosion resistant, Nontoxic and resilient, it plays a dominant role in manufacturing applications. Among the various types of aluminum alloys high silicon alloys where silicon is used as a major alloying element which enhances the mechanical  properties further more as high castability, fluidity. These high silicon alloys are used in great wear applications in engine parts such as pistons, cylinders, and cylinder liners and marine applications. Machining this aluminum alloy with conventional carbide tools and high speed tools results in poor surface finish and tool life. Hence in this research turning operation of silumin alloy with coated carbide inserts was attempted. The carbide tool was coated with aluminum chromium nitride (AlCrN) in mid layer and diamond like carbon (DLC) as top layer. The machining conditions were both wet and dry environments. And the responses like average surface roughness, tool life, tool wear and material removal rate have been found and recorded. Subsequently the responses have been logged in the Minitab software and the optimization progression have been done to find out the finest machining amalgamations.