P| materials Article Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy Hamza A. ALTameemi !©, Thamir Al-Dulaimi1, Michael Oluwatobiloba Awe 2, Shubham Sharma’, Danil Yurievich Pimenov “©, Ugur Koklu °© and Khaled Giasin *O ‘Mechanical Engineering Department, University of Baghdad, Baghdad AHadeya 1070, tra; Hamzaabtameemicorng uobophdad.eduig(H.A.A-T); de thamir720coeng.ucbaghdadeduig (TAD) 223, Guinness Road, Ogba/Taj, Lagos, Nigeria; michael a@tranoag Deparment of Mechanical Eng, IKC Pana Techaical Univesity Jalandhar Kapscthala Road, Kepurtala, Panjab 142503, Inia shubhamStiaharatigmailcom 4) Department of Automated Mechanical Eninocring, South Ural State Ualverity Lenin Prosp. 7, 5080 Chelyabinsk, Rossa; ani érambler ns Department of Mechanical Engineering, Facilty of Engineering, Karamanoglu Mehmetbey Univesity, 700 Karaman, Turkey; ugurkoklu@mal com © School of Mechanical and Design Engineering, University of Portsmouth, Portsmouth POI 3DI, UK Corsespondence: Khaled gssin@port ack Abstract: Aluminum alloys are soft and have low melting temperatures therefore, machining them Oss often results in cut material fusing to the cutting tool due te heat and friction, and thus lowering the " hole quality. A good practice isto use coated cutting tools to overcome such issues and maintain good (Statins AeTameer IEA hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and these types of cutting-tool coating (TIN/TIAIN, TIAIN, and TiN) on the surface Sinish, form, and dimensional tolerances of holes drilled in A16061-T6SI alloy: The study employed, statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each ofthe input parameters on the measured hole-quality outputs (surface-toughness metrics Re and R,, hole size, circularity, perpendicularity, and eylindricity), The highest surface roughness Moana, 1,108 mapa’) OcerReC When Using TIN-coated tools, All holes in this study were oversized regardless ofthe aiorg/05090/man417 178, tool coating or cutting parameters used. TIN tools, which have a lower coating hardness, gave lower hoe citcularity atthe entry and higher cylindicity, while IN/TIAIN and TAIN seemed to be Academic Eitan VicorSengmene more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated Rocied: Meh 221 tecls due to TIN's chemical affinity and low oxidation temperature compared to the TIN/TAIN and ibs Ap 30 THAIN coatings Keywords: AI6061-T651; coating: TIAIN; TIN; TIN/TiAIN; diling; surface roughness; hole size: tier Nate DrLAereretel Grulanty perpendicular; cylin 1. Introduction 2 Aluminum and its alloys are used in many industries, including automotive, building, electrical, and aerospace, owing to characteristics such as low metal density lightweight), durability, electrical conductivity, high strength, corrosion resistance, ductility, and low cost compared with other metals. Aluminum demand is growing worldwide and is expected to grow significantly due to the increased demand as various industries move enltensof the Cratwe covmeee toWard lightweight materials [1,2]. AI6061 is one of the most widely used aluminum. ‘ntnbuton (CC BY} lense ips) alloys in the industry. Its list of applications includes [2]: building material (wide roof Cnathoommarsong/iense/by/_ stractures), welded assemblies, automobiles, aircraft and truck frames, chemical equipment, ton electronic components, fasteners, yacht building, boats and bicycle frames, and camera his ate i an open aces arte Matra 2021, 14,178. Nips /do.ong/10.3990/ena AO7I7SS ‘ilps //wwoemapicom /joural materials