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ARTICLE IN PRESS

International Journal of Machine Tools & Manufacture 48 (2008) 688–697


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Role of second-phase particles in chip breakability in aluminum alloys


Masatsugu Kamiya, Takao Yakou
Department of Mechanical Engineering and Materials Science, Yokohama National University, 79-5 Tokiwadai, Hodogaya-ku, Yokohama 240-8501, Japan
Received 23 May 2007; received in revised form 26 October 2007; accepted 29 October 2007
Available online 6 November 2007

Abstract

To evaluate chip breakability, turning tests for various wrought aluminum (Al) alloys were carried out with a cemented carbide tool
(K10) in dry and wet cutting conditions. In the alloys, Al2Cu, Al6Mn, Mg2Si, Al–Fe–Si system compounds and eutectic Si were observed
as second-phase particles. Chip breakability of the alloys containing Al2Cu or Si were superior to those of those containing Mg2Si or
Al–Fe–Si. This tendency was more prominent in wet cutting than in dry cutting. The second-phase particles of Al2Cu and Si in these
alloys fractured during the machining process. It was estimated that the fractured second-phase particles acted as the cause of chip
breaking. Moreover, the increase of the chip breakability in wet cutting was attributed to the Rehbinder effect due to the penetration of
cutting oil into the micro-cracks.
r 2007 Elsevier Ltd. All rights reserved.

Keywords: Aluminum alloys; Turning; Machinability; Chip breakability; Second-phase particle

1. Introduction particles to replace Pb [1]. In that research, the cracking of


Si particles in chips and the breaking of short chips into
Machinability of metals has been estimated by the pieces during machining were observed. Moreover, in
cutting force, tool life, surface finish and chip shape. A6061 alloys with Si particles, the Si particles were cracked
However, since the rigidity of machine tools has been because of concentration of strain [2], and the Si particles
increased, the cutting force is no longer considered in the in the alloys became the stress concentration zone in shear
machining of aluminum (Al) alloys. As a result, tool life, deformation [3]. On the other hand, in the research of
surface finish and chip shape have become major factors of the relationship between chip breakability and aging
machinability. Particularly, chip breakability is emphasized treatment in Al–Cu and Al–Cu–Si alloys [4–7], the chip
as the most important feature to ensure reliable operation breakability successfully improved with increased size of
in automated machining. One of the approaches for second-phase particles accompanied by advanced aging.
improving machinability is the use of free-cutting alloys. In this case, however, it has been pointed out that the
It has been considered that the addition of lead (Pb) to Al chip breakability was also related to the cracking of the
alloys is the principal method to improve machinability, second-phase particles and the ductility of the matrix
and processes of adding Pb to 2XXX and 6XXX series around them [7].
alloys have been developed. However, because of its Anyhow, these facts suggest that the chip breakability
adverse environmental impact, the addition of Pb has been of Al alloys is expected to improve by the dispersion
restricted. Therefore, the development of new free-cutting of some kind of second-phase particles, and the second-
Al alloys without Pb is required. phase particles could be the cause of chip breaking by
There has been an attempt to improve the chip break- cracking during machining. There are various second-
ability of Al alloys by the dispersion of Si as second-phase phase particles, including precipitates and crystallized
particles, in commercial Al alloys. In this study, the
Corresponding author. Tel./fax: +81 45 3393845. influence of such second-phase particles in commercial
E-mail address: d02sa301@ynu.ac.jp (M. Kamiya). Al alloys on chip breakability was investigated using

0890-6955/$ - see front matter r 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2007.10.018
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Table 1
Chemical compositions of specimens (mass%)

Material Si Fe Cu Mn Mg Cr Zn Ni Ti Zr+Ti Al

Alloy Treatment

A2017 T4 0.54 0.21 3.88 0.65 0.59 0.01 0.02 o0.01 0.02 0.02 bal.
A3003 O 0.10 0.39 0.12 1.10 o0.01 o0.01 o0.01 o0.01 o0.01 o0.01 bal.
A4032 T651 11.5 0.17 0.90 0.01 1.00 o0.01 o0.01 0.87 o0.01 o0.01 bal.
A5056 H34 0.11 0.17 0.02 0.06 4.93 0.06 o0.01 o0.01 0.02 o0.01 bal.
A6061 T6 0.71 0.20 0.29 0.12 1.00 0.18 0.03 o0.01 0.02 o0.01 bal.
A7075 T6511 0.04 0.23 1.32 0.02 2.18 0.20 5.35 o0.01 0.03 0.03 bal.
Al–12%Si F 12.0 0.14 0.02 o0.01 0.02 o0.01 0.01 o0.01 o0.01 o0.01 bal.

2XXX, 3XXX, 4XXX, 5XXX, 6XXX and 7XXX series 6°


Al alloys.

2. Experimental procedure

The materials used in the experiments were wrought 5°


aluminum alloys A2017, A3003, A4032, A5056, A6061
and A7075. Al–12mass%Si alloy (Al–12%Si), which
is produced by continuous casting, was also used in
this experiment. The chemical compositions of the materi- 6°
30°
als are shown in Table 1. Each material was treated

R=
with a type of thermo-mechanical treatment used in

0.4
industry. The thermo-chemical treatments are also listed 90°

mm
in Table 1.
From the chemical composition of the alloys shown in
Table 1, it is expected that the existence of second-phase
particles is as follows: Al2Cu and Al2CuMg for A2017;
Al6Mn and Al–Fe–Si for A3003; Si, Mg2Si and Al–Fe–Si
for A4032; Mg2Si and Al–Fe–Si for A6061; Al2Cu,
Al2CuMg and Mg2Si for A7075; and eutectic Si and Fig. 1. Geometry of tool cutting edge used in the experimental study.
Al–Fe–Si for Al–12%Si [8].
The cutting tests were performed on a lathe. The depth
of cut t and feed rate f were 0.5 mm and 0.1 mm/rev,
respectively, and the cutting speed V was varied from 0.5 somewhat large. However, by referring to the phase
to 1.5 m/s. Carbide cutting tool inserts (Tungaloy TPGN- diagram, the second-phase particles contained in each
160304-K10) with a positive 51 rake angle, shown in Fig. 1, alloy were thought to be as follows: the white particles in
were used in the experiment. The cutting tests were carried A2017 Fig. 2(a) to be Al2Cu; the white particles in A3003
out under dry and wet conditions. Compounded cutting oil Fig. 2(b) to be Al6Mn; the black particles in A4032
was used as a lubricant. Fig. 2(c) to be Si and the white particles to be Al–Fe–Si; the
black particles in A5056 Fig. 2(d) to be Mg2Si and the
3. Results white particles to be Al–Fe–Si; the black particles in A6061
Fig. 2(e) to be Mg2Si and the white particles to be
3.1. Second-phase particles in Al alloys Al–Fe–Si; the black particles in A7075 Fig. 2(f) to be Mg2Si
and the white particles to be Al2Cu; and the gray particles
The second-phase particles were observed with an in Al–12%Si Fig. 2(g) to be Si and the white particles to be
electron probe X-ray microanalyzer (EPMA). Fig. 2 Al–Fe–Si.
shows the secondary electron images of the specimens, Fig. 3 shows the Vickers hardness measured with an
and Table 2 shows the results of the EPMA analysis. The indentation force of 0.03 N (the size of indentation was
spot size of the EPMA was bigger than the second-phase about 2 mm so that we could measure the hardness of the
particles in the specimens, even though the size of the second-phase particles). The dashed lines in the graphs in
EPMA spot was made as small as possible; therefore, Fig. 3 indicate the hardness calculated from tensile strength
the quantities of aluminum detected in the analysis were sB using the equation HVffi3sB [9]. The calculated
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A2017 A3003

1(A)
2
2 1(B)

A4032 A5056

2(D)
1(D)
4 1(C)

2(E)
3

3(E)

A6061 A7075
2(E)

1(D)

1(D)

3
3
2(A)

Al-12%Si
1(C)

2(E) 3

5 µm

Fig. 2. SEM micrographs of second-phase particles in specimens: (A) Al2Cu, (B) Al6Mn, (C) Si, (D) Mg2Si and (E) Al–Fe–Si.

hardness is considered to be the hardness of the matrix of hardness of Al2Cu, Mg2Si and Si is HV400–700 [10],
the alloys. In each alloy, the data of the hardness was HV450 [11], HV900–1100 [12], respectively. The maximum
categorized into two groups. The groups with the lower hardness values in Fig. 3 are in good agreement with these
hardness represent the hardness of the matrix without the values.
second-phase particles, and the groups with the higher
hardness represent the hardness of the second-phase 3.2. Chip breakability of Al alloys in dry cutting
particles or the matrix including the second-phase particles.
So the maximum hardness in the group of higher hardness Fig. 4 shows photographs of the chip shapes formed
represents the hardness of the second-phase particles. The in dry cutting. The chip shape strongly depends on the type
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Table 2
Measurement results of quantitative analysis by EPMA (at%)

Material Measured point indicated in Fig. 2 Al Si Fe Cu Mn Mg Zn

A2017 1 90.68 – – 9.31 – – –


2 98.01 – – 1.99 – – –
A3003 1 89.50 – 4.22 – 6.28 – –
2 99.68 – 0.01 – 0.31 – –
A4032 1 30.27 69.52 0.01 – – 0.21 –
2 14.01 17.60 0.01 – – 68.37 –
3 96.73 1.00 2.26 – – 0.01 –
4 96.73 0.41 0.02 – – 0.66 –
A5056 1 47.00 18.14 0.01 – – 34.85 –
2 91.32 3.39 5.07 – – 0.22 –
3 94.16 0.08 0.09 – – 5.67 –
A6061 1 57.16 7.50 0.07 – – 35.27 –
2 90.06 3.16 6.38 – – 0.40 –
3 98.63 0.26 0.17 – – 0.95 –
A7075 1 85.70 9.09 – 0.50 – 2.46 2.25
2 79.81 0.05 – 18.59 – 0.50 1.06
3 94.19 0.04 – 0.57 – 2.67 2.52
Al–12%Si 1 31.89 37.54 0.08 – – – –
2 79.11 5.36 15.54 – – – –
3 99.36 0.63 0.01 – – – –

1200

1000
Vickers hardness HV0.03

800

600

400

200

0
A2017 A3003 A4032 A5056 A6061 A7075 Al-12%Si

Fig. 3. Micro Vickers hardness of specimens.

of Al alloy, and was slightly affected by cutting speed. for A5056 and A6061; and about 102 for A3003 and
Especially, the chip shape of A7075 tends to be conti- A7075.
nuous; it was tangled with the cutting tool during
machining. On the contrary, the other alloys, A2017, 3.3. Chip breakability of Al alloys in wet cutting
A3003, A4032, A5056, A6061 and Al–12%Si, are broken
apart. To evaluate the chip breakability from the Fig. 6 shows photographs of the chip shapes formed in
chip shape in these photographs, we defined the ‘‘chip- wet cutting. In wet cutting, the chip of A7075 is
breaking factor N’’ as a parameter of chip breakability, continuous, as in the dry cutting; the chips of the other
which was determined by measuring the number of chips alloys are smaller than those in dry cutting. Especially,
contained in a 100 g sample of chips. According to Asano the chips of A2017, A4032 and Al–12%Si are much
and Fujiwara [13], the chip breakability is optimum in the smaller than those of the other alloys. Fig. 7 shows
range of 104oNo105. Fig. 5 shows the chip-breaking the chip-breaking factor for various alloys in wet
factor for various Al alloys. The chip-breaking factor cutting. The chip-breaking factor in wet cutting shows
shows 103–104 for A2017, A4032 and Al–12%Si; about 103 a similar tendency to that in dry cutting; however,
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692 M. Kamiya, T. Yakou / International Journal of Machine Tools & Manufacture 48 (2008) 688–697

V = 0.5m/s V = 1.0m/s V = 1.5m/s

A2017-T4
A3003-O
A4032-T651
A5056-H34
A6061-T6
A7075-T6511
Al-12%Si-F

Fig. 4. Chip shapes formed in dry cutting.


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Chip breaking factor, N (per 100g)


105 V=0.5m/s
V=1.0m/s
V=1.5m/s
104

103

102

A2017 A3003 A4032 A5056 A6061 A7075 Al-12%Si

Fig. 5. Chip-breaking factor N for various aluminum alloys in dry cutting.

the difference between these alloys becomes clear. contain these second-phase particles and showed large chip
The chip breakability shows a remarkably large value in breakability, it is considered that cracked Al2Cu and Si
A2017, A4032 and Al–12%Si, and reaches 2  105 at a acted as the cause of chip breaking.
maximum. Fig. 9 shows the relation between the chip-breaking
factor N and the volume fraction Vf of the second-phase
4. Discussion particles in the alloys. A2017, A4032, A5056, A6061 and
Al–12%Si have a linear relation between N and Vf in both
4.1. Classification of materials by chip dry and wet cutting. These alloys belong to Groups I or II.
As mentioned above, the cracked Al2Cu and Si particles in
To summarize the results, the materials used in the alloys belonging to Group I seem to act as the cause of chip
experiment could be classified into three groups depending breaking. The alloys of Group II also show a linear relation
on the chip-breaking factor. The grouping is shown in similar to that for Group I. This fact suggests that the chip
Table 3. In Group I, N is 103–104 in dry cutting and breaking of the alloys of Group II is due to the cracking of
104–105 in wet cutting. A2017, A4032 and Al–12%Si second-phase particles. It is reported that nearly half of the
belong to this group. The second-phase particles in the Mg2Si particles around the cracks caused by the tensile test
alloys that belong to this group are Al2Cu, Si, Mg2Si and were fractured or broken away at the matrix interface [14].
Al–Fe–Si. In Group II, N is around 103 in both dry and wet While we could not observe the fracture of Mg2Si, Mg2Si is
cutting. A5056 and A6061 belong to this group. Mg2Si and also thought to have an effect as a cause of chip breaking.
Al–Fe–Si exist in these alloys. In Group III, N is around Moreover, the alloys of Groups I and II, in which fractured
102 in both dry and wet cutting. A3003 and A7075 belong second-phase particles act as the cause of chip breaking,
to this group. Al6Mn, Al2Cu, Mg2Si and Al–Fe–Si are show a greater N in wet cutting than that in dry cutting. On
observed in these alloys. We will continue our discussion by the other hand, Al6Mn in A3003, which is in Group III, has
focusing on the second-phase particles that exist in each no effect on chip breaking because they do not fracture
group. during machining as shown in Fig. 8.
A7075 shows an obviously different property from the
4.2. Relation between existence of second-phase particles other alloys. The chip of A7075 was continuous in any
and chip breakability cutting conditions, although A7075 contains second-phase
particles Al2Cu and Mg2Si. It is known that superplasticity
Fig. 8 shows cross-sectioned micrographs of the chips at occurs in fine-grained A7075 [15,16]. Moreover, it has been
a cutting speed of 1.0 m/s in dry cutting. Compared with reported that the chip of Al–Zn eutectoid alloy, which
Figs. 2 and 8, cracked second-phase particles are observed shows superplasticity, is continuous [17]. Fine-grained
in the chips. Cracked Al2Cu is observed in A2017, cracked A7075 shows prominent superplasticity at a strain rate of
Si is observed in A4032 and in Al–12%Si. However, there 103 s1 and at a temperature of 520 1C [16]. The strain rate
are no cracked Al6Mn particles in A3003 and no cracked in metal cutting is considerably faster, 105 s1, than that for
Mg2Si particles in A5056 and A6061. This observation superplasticity [18]. It has not been clarified that super-
suggests that second-phase particles have different fracture plasticity occurs at the high strain rate of 105 s1 for A7075.
strengths. It can be stated that Al2Cu and Si could be easily There is a possibility that superplasticity occurs in A7075
cracked during machining. Since the alloys in Group I machining; however, this remains to be solved.
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694 M. Kamiya, T. Yakou / International Journal of Machine Tools & Manufacture 48 (2008) 688–697

V = 0.5m/s V = 1.0m/s V = 1.5m/s

A2017-T4
A3003-O
A4032-T651
A5056-H34
A6061-T6
A7075-T6511
Al-12%Si-F

Fig. 6. Chip shapes formed in wet cutting.


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Chip breaking factor, N (per 100g)


105 V = 0.5 m/s
V = 1.0 m/s
V = 1.5 m/s
104

103

102

A2017 A3003 A4032 A5056 A6061 A7075 Al-12%Si

Fig. 7. Chip-breaking factor N for various aluminum alloys in wet cutting.

Table 3
Classification of materials by chip-breaking factor N

Group Material Second-phase particle Chip-breaking factor N

Group I A2017 Al2Cu Dry cutting: 103–104


A4032 Si, Mg2Si, Al–Fe–Si Wet cutting: 104–105
Al–12%Si Si, Al–Fe–Si
Group II A5056 Mg2Si, Al–Fe–Si Dry cutting: 103
A6061 Mg2Si, Al–Fe–Si Wet cutting: 103
Group III A3003 Al6Mn, Al–Fe–Si Dry cutting: 102
A7075 Al2Cu, Mg2Si Wet cutting: 102

4.3. Chip breakability in dry and wet cutting 5. Conclusions

As shown in Fig. 9, the chip breakability of the materials The role of second-phase particles on the chip break-
belonging to Group I or II in wet cutting is much greater ability of Al alloys has been investigated with turning tests
than that in dry cutting. Here, we discuss the reason. for various wrought aluminum alloys. The main results are
Rehbinder [19] have reported a reduction of cutting force as follows:
when liquid containing an organic polar compound is
applied on the surface of workpieces; this phenomenon is
known as the Rehbinder effect. The reason for the (1) The alloys used in the experiment could be classified
occurrence of the Rehbinder effect in machining is that into three groups depending on the chip-breaking
embrittlement of metals results from the decrease of surface factor. This is due to the difference of the breakability
energy and the prevention of re-welding of micro-cracks due of second-phase particles in these materials.
to the lubricants [20]. The materials belong to Group I or II (2) The chip breakability increases in alloys with Al2Cu or
are the ones in which cracked second-phase particles act as Si, and this tendency appears more remarkably in wet
the cause of chip breaking. Such cracking of second-phase cutting than in dry cutting. The increase of chip
particles and interface debonding between matrix and breakability is due to the fracture of second-phase
second-phase particles lead to the generation of micro- particles during machining.
cracks. It is considered that the increase of chip breakability (3) The increase of chip breakability in wet cutting is
in wet cutting can be attributed to the Rehbinder effect due attributed to the Rehbinder effect, which results from
to the penetration of cutting oil into the micro-cracks. the penetration of cutting oil into micro-cracks.
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A2017 A3003

A4032 A5056

A6061 A7075

Al-12%Si

10µm

Fig. 8. Optical micrographs of cross section of chip at cutting speed 1.0 m/s in dry cutting. Arrows indicate cracks in second-phase particles.
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