Aluminium binary alloys were prepared into plates with 0.34∼19.8% magnesium, highly soluble in aluminium; with 0.03∼3.00% manganese, slightly soluble in aluminium; and with 0.53∼2.30% iron, almost insoluble in aluminium. Low-speed orthogonal cutting was abruptly stopped and the built-up edge formed around the tool tip was observed. In this experiment, typical nose type built-up edges were recognized in Al-Mg alloys and Al-(2.70∼3.00%)Mn alloys, and plate type built-up edges were observed in Al-Fe alloys and Al-(0.03∼1.12%)Mn alloys.
In the case of nose type built-up edges, the faster the cutting speed or the smaller the rake angle, the larger the figure of built-up edge. In the case of Mg addition, the alloy containing 8.19%Mg showed the largest built-up edge. The shape of the built-up edge was in substantial agreement with Hoshi’s form,
y=(1⁄4
t)
x2 (where
x: horizontal length of the built-up edge,
y: vertical length of the built-up edge and
t: depth of the cut), except the cases of very low cutting speed and small rake angle. In the growing stage of the built-up edge, the cutting resistance showed overrunning and the cut surface was deteriorated. However, as the built-up edge became stabilized, the cutting resistance decreased in some measure and showed a stationary state, resulting in improvement of the cut surface which is called “the cutting transient phenomena”.
In the case of plate type built-up edges, the built-up edge grew of a certain size adhered on the tool surface in the early cutting stage and no remarkable change was caused by the progression of cutting, thus indicating little variation in cutting resistance. But, as the plate type built-up edge grew, the cut surface became deteriorated with the rise of cutting speed.
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