Investigation into the Effects of Tool Geometry and Metal Working Fluids on Tool Forces and Tool Surfaces During Orthogonal Tube Turning of Aluminum 6061 Alloy

Abstract

Orthogonal Metal Cutting has evolved as a significant way of analyzing the mechanics involved in the art of metal cutting. An orthogonal tube turning apparatus was constructed and validated. The instrument was used to investigate the effects of back rake angle, uncut chip thickness and cutting environments on the tool forces generated during tube turning. Surface roughness was used to parameterize tool surface finish for cutting each factor level combination of the experiment. This work empirically documents the variation of tool forces and tool surface roughness under the influence of various cutting parameters. Force ratios and shear plane angles are calculated using the classical metal cutting equations, analyzing the behavioral patterns and interdependence of cutting forces, tool surface roughness and shear angle.