Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

M. Azizur Rahman; Md Shahnewaz Bhuiyan; Sourav Sharma; Mohammad Saeed Kamal; M. M. Musabbir Imtiaz; Abdullah Alfaify; Trung-Thanh Nguyen; Navneet Khanna; Shubham Sharma; Munish Kumar Gupta; Saqib Anwar; Mozammel Mia

doi:10.3390/met11010159

Metals (Jan 2021)

Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy

M. Azizur Rahman,
Md Shahnewaz Bhuiyan,
Sourav Sharma,
Mohammad Saeed Kamal,
M. M. Musabbir Imtiaz,
Abdullah Alfaify,
Trung-Thanh Nguyen,
Navneet Khanna,
Shubham Sharma,
Munish Kumar Gupta,
Saqib Anwar,
Mozammel Mia

Affiliations

M. Azizur Rahman: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
Md Shahnewaz Bhuiyan: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
Sourav Sharma: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
Mohammad Saeed Kamal: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
M. M. Musabbir Imtiaz: Department of Mechanical and Production Engineering, Ahsanullah University of Science and Technology, Dhaka 1208, Bangladesh
Abdullah Alfaify: Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
Trung-Thanh Nguyen: Department of Manufacturing Technology, Le Quy Don Technical University, 236 Hoang Quoc Viet, Ha Noi 100000, Vietnam
Navneet Khanna: Advanced Manufacturing Laboratory, Institute of Infrastructure Technology, Research and Management, Ahmedabad 380026, India
Shubham Sharma: Department of Mechanical Engineering, IKG Punjab Technical University, Jalandhar-Kapurthala Road, Kapurthala, Punjab 144603, India
Munish Kumar Gupta: Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan 250061, China
Saqib Anwar: Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
Mozammel Mia: Department of Mechanical Engineering, Imperial College London, London SW7 2AZ, UK

DOI: https://doi.org/10.3390/met11010159
Journal volume & issue: Vol. 11, no. 1
p. 159

Abstract

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In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

Published in Metals

ISSN: 2075-4701 (Online)
Publisher: MDPI AG
Country of publisher: Switzerland
LCC subjects: Technology: Mining engineering. Metallurgy
Website: http://www.mdpi.com/journal/metals

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