Effect of cutting parameters on heat generation in ultra-precision milling of aluminum alloy 6061

This paper aims to study the cutting-induced heat generation on the machined surface in ultra-precision raster milling (UPRM) by using the time-precipitates-temperature characteristics of aluminum alloy 6061 (al6061). The influences of cutting parameters including depth of cut, spindle speed, and cutting feed rate on heat generation in UPRM are investigated. Isothermal heat treatment is used to build the relationship between the heating time, heating temperature, and average size of the generated precipitates for al6061 alloy. Single cutting tests are conducted to study heat distribution in one revolution during raster milling process, and surface milling is employed to study the influences of cutting parameters on the heat generation and temperature rise on the ultra-precision milled surface. The experimental results show that the increases of spindle speed and feed rate generate more heat during raster milling process while the decrease of depth of cut firstly decreases then increases the temperature rise on the machined al6061. The scratch marks due to the cutting-induced precipitates are dependent on the cutting parameters.

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