Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russia

Е. G. Zlotnikov, Associate Professor of the Department of Mechanical Engineering, Candidate of Technical Sciences, e-mail: Zlotnikov_EG@pers.spmi.ru
А. А. Dzyuba, Student of the Department of Mechanical Engineering, e-mail: s210470@stud.spmi.ru

The influence of silicon impurities in the structure of the hypereutectic aluminum-silicon alloy AK21M3N1 on tool wear during mechanical cutting has been evaluated. It is noted that hypereutectic aluminum-silicon alloys, having positive properties as a structural material, have certain processing difficulties caused by the presence of a high content of primary silicon crystals in the structure of these alloys, which leads to intense abrasive wear of the cutting tool. In this regard, the aim of this research is to study the effect of different structures of the hypereutectic aluminum-silicon alloy on the nature and rate of tool wear. In the course of the study, two samples made of AK21M3N1 rod material were processed by the external turning method. One of the samples had a fine-grained structure with an average equivalent diameter of primary silicon crystals of 45 microns, and the second had a coarse-grained structure with a primary silicon crystal size of 86 microns. The tools selected are cutters with a hard alloy of the tungsten-cobalt group of the VK6-OM grade (fine-grained), which has increased strength. The two samples were processed without the cutting compound with the same geometry of the cutters and cutting modes, each with five passes with a total working duration of 450 s (7.5 min). Wear and changes in the geometry of the cutters were estimated by photographs of the back and front surfaces of the tools. When processing a sample of fine-grained structure with a higher hardness of the material (110 HB), in addition to abrasive wear, the phenomenon of thermal softening, plastic deformation and shear of the tool material along the back surface was detected. For a sample of coarse-grained structure with a lower hardness of the material (92 HB), abrasive wear on the back surface prevails. The roughness parameters of the processed samples surfaces after the 5th pass meet the requirements of finish machining. An analysis of the changes in geometry along the front surface allows for the conclusion that due to wear, there is an increase in the radius at the tip of the cutters, which is greater in value for a sample with a coarse-grained structure. These data must be taken into account and corrected when adjusting the tool to the size of the processed surface.

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