Abstract
The microstructures, machinability and surface characteristics of Al-7Si and Al-7Si-2.5Cu cast alloys were studied after various melt treatments like grain refinement and modification. The results indicate that combined grain refined and modified Al-7Si-2.5Cu cast alloys have microstructures consisting of uniformly distributed α-Al grains, eutectic Al-silicon and fine CuAl2 particles in the interdendritic region. These alloys exhibited better machinability and surface characteristics in the cast condition compared with the same alloy subjected to only grain refinement or modification. Performances of the turning inserts (uncoated and polished CVD diamond coated) were evaluated in machining Al-7Si and Al-7Si-2.5Cu cast alloys under dry environment using a lathe. The polished CVD diamond coated insert outperformed the uncoated cutting insert which suffered from sizeable edge buildup leading to higher cutting force and poor surface finish. The polished CVD diamond coated insert shows a very small steady wear without flaking of the diamond film during cutting. This paper attempts to investigate the influence of grain refinement, modification and combined action of both on the microstructural changes in the Al-7Si and Al-7Si-2.5Cu cast alloys and their machinability and surface finish when different turning inserts are used.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
ASM Handbook 1989a Casting (Metals Park, Ohio: ASM International) pp 785–791
ASM Handbook 1989b Selection and properties of non-ferrous materials (Metals Park, Ohio: ASM International) Vol. 2, pp 1223–1240
Basavakumar K G, Mukunda P G and Chakraborty M 2006 Trans. Indian Inst. Met. 59 400
Brechet Y, Embury J D, Tao S and Luo L 1991 Acta Metall. & Mater. 39 1781
Chamberlain B 1979 Machinability of aluminium alloys, in Metals handbook, properties and selection: nonferrous alloys and pure metals (ASTM G-4) 9th edn, Vol. 2, pp 187–190
Grum J and Kisin M 2003 Int. J. Mach. Tools & Manu. 43 1535
Grum J and Kisin M 2005 Mach. Tool & Manu. 1
Konig W and Erinski D 1983 Ann. CIRP 32 535
Kori S A, Murthy B S and Chakraborthy M 2000 Mater. Sci. & Eng. A283 94
Malshe A P, Park B S, Brown W D and Naseem H A 1999 Int. J. Diamond Relat. Mater. 8 1198
Mondolfo L F 1979 Aluminium: structures and properties (England: Butterworths) pp 756–775
Prabhu U A, Malshe A P and Batzer S A 2006 Int. J. Surf. & Coating Technol. 3399
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Basavakumar, K.G., Mukunda, P.G. & Chakraborty, M. Influence of melt treatments and polished CVD diamond coated insert on cutting force and surface integrity in turning of Al-7Si and Al-7Si-2.5Cu cast alloys. Bull Mater Sci 30, 427–437 (2007). https://doi.org/10.1007/s12034-007-0069-7
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12034-007-0069-7