Effect of cutting parameters and machining environments on the chips characteristics and surface quality of commercial high-conductive materials

The present paper is on the physical and mechanical characterization of machined chips of commercially available highly conductive materials, namely aluminium and copper under different machining environments. More specifically, geometry and hardness of chips as well as the chips removal effect on the machined surfaces are investigated in a quantitative fashion as a function of machining fluid and cutting parameter. The machining is carried out using a horizontal shaper machine with a V-shaped HSS tool under three different machining fluids, where the feed rate is kept constant, while the cutting speed and depth of cut are varied. Results show that chips attain the lower hardness in dry machining conditions than those of under kerosene and soluble oil as a phenomenon alike to hot rolling. Discontinuous chips are formed at low depth of cut for Al and higher depth of cut for Cu in dry condition. Cutting fluid offer improved surface quality through less friction and built up edge formation. Cu generates more heat than Al since copper is harder than aluminum and cutting speed is more effective than depth of cut.