Abstract
The built-up edge in machining of an aluminum alloy is an important problem, and its shape affects the cutting state of the alloy. The aim of this study is to elucidate the main cause of the shape change of the built-up edge. The effect of the shape of the built-up edge on the cutting process was also investigated. The shape of the built-up edge can be roughly classified into two types: the wedge type and nose type. The machining of Al-Mg alloys results in the formation of the wedge type built-up edge which remains on the tool face. The addition of Si or Bi to a work material of an aluminum results in the formation of the nose type built-up edge. The wedge type built-up edge was observed in machining of alloys with high hardness and high work hardenability. While the cutting force, surface roughness and affected-layer depth decrease in the case of the wedge type built-up edge, these values increase in the case of the nose type built-up edge.
