Reliability Analysis of Single Point Cutting Tool on Al6063 Alloy
Keywords:
DOE, Flank wear, HSS tool, Process parameters, Reliability, Resultant ForceAbstract
This study aims to investigate the Al6063 alloy machining reliability of a single point cutting tool. Because of its well-known advantageous mechanical qualities, Al6063 can be used in a wide range of applications. The machining results are highly impacted by tool wear, such as flank wear, which makes prompt tool replacement necessary to preserve component quality and production efficiency. To assess tool performance, the experiment used High-Speed Steel (HSS) tools under various cutting conditions, such as speed, feed, depth of cut, and rake angle. Using image processing methods, flank wear was assessed, and experimental data was used to simulate its distribution as a normal distribution. The probability that the cutting tool would function satisfactorily for the designated amount of time before needing to be replaced was ascertained using reliability analysis. The findings show that increased cutting forces improve tool reliability; in fact, some experiments had reliability percentages above 75%. The results highlight how crucial it is to maximize machining parameter optimization to extend tool life and reduce operational disturbances. To increase manufacturing productivity and quality assurance in Al6063 alloy applications, future research might concentrate on further optimizing these parameters and confirming the findings across various tool materials and machining environments.
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