Analysis of Tool Performance during Ball-End Milling of Aluminium Alloy 6061-T6

This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coated carbide under dry cutting condition. Cutting parameters selected were cutting speed, Vc = 115-145 m/min; feed rate fz = 0.15-0.2 mm/tooth and depth of cut, ap = 0.5-0.75 mm. The result showed the tool life of PVD TiAlN ranged from 11 to 97 min. Full factorial approach was employed to exhibit relationship between parameter input and output. From the analysis, cutting speed was found to be the most significant factor for tool performance followed by feed rate and depth of cut. It was also found that most of failure modes occurred were notch wear and flaking near those found near depth of cut line.