Experimental and 3D-Deform Finite Element Analysis on Tool Wear during Turning of Al-Si-Mg Alloy

Aluminum alloys are becoming increasingly significant in the manufacturing industry due to their light weight and durable properties. Widely applied in aerospace and construction, precision machining is required to ensure the best possible surface quality. The surface quality of a machined component is directly affected by the tool wear incurred during machining. This research investigated the effect of process parameters and machining conditions on tool wear. The critical process parameters selected were cutting speed, feed rate, and depth of cut. Multi-walled carbon nanotube particles were dispersed in a base fluid of mineral oil to create a new lubricant applied during machining. Pure mineral oil was also used as a lubricant to reduce friction. Machining experiments were carried out with the two lubricants, and the tool wear incurred was measured and compared using a Dinolite microscope. All experiments were carried out with high-speed steel (HSS) cutting tools. Taguchi’s L9 orthogonal array was employed as a methodology to design the experiments. A finite-element 3D simulation was also carried out using DEFORM-3D to provide a scientific explanation of the turning process. Results showed a significant reduction in tool wear when machining with multi-walled carbon nanotubes (MWCNTs), with an average reduction of 14.8% compared to mineral oil. The depth of cut was also the most influential process parameter in terms of tool wear.