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10.3390/ma14071783
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Article

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

by
Hamza A. Al-Tameemi
1,
Thamir Al-Dulaimi
1,
Michael Oluwatobiloba Awe
2,
Shubham Sharma
3,
Danil Yurievich Pimenov
4,
Ugur Koklu
5 and
Khaled Giasin
6,*
1
Mechanical Engineering Department, University of Baghdad, Baghdad Al-Jadriya 10070, Iraq
2
22a, Guinness Road, Ogba/Ikeja, Lagos, Nigeria
3
Department of Mechanical Eng., IKG Punjab Technical University, Jalandhar-Kapurthala Road, Kapurthala, Punjab 144603, India
4
Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, 454080 Chelyabinsk, Russia
5
Department of Mechanical Engineering, Faculty of Engineering, Karamanoglu Mehmetbey University, 70100 Karaman, Turkey
6
School of Mechanical and Design Engineering, University of Portsmouth, Portsmouth PO1 3DJ, UK
*
Author to whom correspondence should be addressed.
Materials 2021, 14(7), 1783; https://doi.org/10.3390/ma14071783
Submission received: 2 March 2021 / Revised: 31 March 2021 / Accepted: 2 April 2021 / Published: 4 April 2021
(This article belongs to the Special Issue Additive and Subtractive Manufacturing of Advanced Materials: Applications, Future Trends and Perspectives of Industry 4.0)
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Abstract

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.
Keywords: Al6061-T651; coating; TiAlN; TiN; TiN/TiAlN; drilling; surface roughness; hole size; circularity; perpendicularity; cylindricity Al6061-T651; coating; TiAlN; TiN; TiN/TiAlN; drilling; surface roughness; hole size; circularity; perpendicularity; cylindricity

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MDPI and ACS Style

Al-Tameemi, H.A.; Al-Dulaimi, T.; Awe, M.O.; Sharma, S.; Pimenov, D.Y.; Koklu, U.; Giasin, K. Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy. Materials 2021, 14, 1783. https://doi.org/10.3390/ma14071783

AMA Style

Al-Tameemi HA, Al-Dulaimi T, Awe MO, Sharma S, Pimenov DY, Koklu U, Giasin K. Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy. Materials. 2021; 14(7):1783. https://doi.org/10.3390/ma14071783

Chicago/Turabian Style

Al-Tameemi, Hamza A., Thamir Al-Dulaimi, Michael Oluwatobiloba Awe, Shubham Sharma, Danil Yurievich Pimenov, Ugur Koklu, and Khaled Giasin. 2021. "Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy" Materials 14, no. 7: 1783. https://doi.org/10.3390/ma14071783

APA Style

Al-Tameemi, H. A., Al-Dulaimi, T., Awe, M. O., Sharma, S., Pimenov, D. Y., Koklu, U., & Giasin, K. (2021). Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy. Materials, 14(7), 1783. https://doi.org/10.3390/ma14071783

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