Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy

Machining is a process to manufacture a product by removing portion of material by using cutting tool. In machining aluminium alloy, the usage of high speed steel (HSS) cutting tool have dominant due to versatility and superior hardness. However, HSS cutting tool is very prone to wear in high-speed...

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Main Author:	Mohd Rashid, Mohd Fairuz
Format:	Thesis
Language:	English English
Published:	2021
Subjects:	T Technology (General) TJ Mechanical engineering and machinery
Online Access:	http://eprints.utem.edu.my/id/eprint/26084/1/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf http://eprints.utem.edu.my/id/eprint/26084/2/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf
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spelling	my-utem-ep.260842023-01-16T14:58:42Z Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy 2021 Mohd Rashid, Mohd Fairuz T Technology (General) TJ Mechanical engineering and machinery Machining is a process to manufacture a product by removing portion of material by using cutting tool. In machining aluminium alloy, the usage of high speed steel (HSS) cutting tool have dominant due to versatility and superior hardness. However, HSS cutting tool is very prone to wear in high-speed machining due to the low hot hardness. Such condition affected productivity as worn cutting tool detrimental to the machined surface and the production need to stop to replace the cutting tool. In the recent advancement of machine tool technology, a new type of steel already applied for automotive structure. This steel, named as 22MnB5 Boron Steel, produced by the hot stamping process where the sheet metals were formed and heat treated inside metal stamping dies. 22MnB5 Boron Steel categorized as ultra-high strength steel with 1500 MPa tensile strength and 80 HRC hardness. Such properties resembled almost similar to HSS which make them potential to be applied as cutting tool. The purpose of this study is to investigate the capability of 22MnB5 Boron Steel as a cutting tool in machining aluminium alloy. Initial part of study involved with analysis on the physical and mechanical properties of 22MnB5 in terms of hardness, density, tensile strength, surface appearance and coefficient of friction. The second part covers machining trials of 22MnB5 Boron steel on Al 6061 Aluminum Alloy using various condition and parameters. Lastly the third parts cover assessment of failure modes and wear mechanism of 22MnB5. The results show that combination of high hardness of 70HRC, density of 7.841 g/cm3 and tensile strength of 1500 MPa facilitate strong edge of 22MnB5 to machine Al 6061 smoothly. 22MnB5 capable to machine Al 6061 Aluminum Alloy in wet condition up to 861 s at 200 m/min, 0.1 mm/rev and 0.5 mm cutting speed, feed rate and depth of cut respectively. The wear mechanism showed up as fragmented debris and built up layer dominated the flank and crater surfaces with abrasive and adhesive effects. This study built better understanding of 22MnB5 characterization in operation that involved with friction, tribology and machining. Finding from this study could also benefit the industries in terms of selection of cutting tools that capable to machine product with sustainable manufacturing approach. 2021 Thesis http://eprints.utem.edu.my/id/eprint/26084/ http://eprints.utem.edu.my/id/eprint/26084/1/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf text en public http://eprints.utem.edu.my/id/eprint/26084/2/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=121298 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Abu Bakar, Mohd Hadzley
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Abu Bakar, Mohd Hadzley
topic	T Technology (General) TJ Mechanical engineering and machinery
spellingShingle	T Technology (General) TJ Mechanical engineering and machinery Mohd Rashid, Mohd Fairuz Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
description	Machining is a process to manufacture a product by removing portion of material by using cutting tool. In machining aluminium alloy, the usage of high speed steel (HSS) cutting tool have dominant due to versatility and superior hardness. However, HSS cutting tool is very prone to wear in high-speed machining due to the low hot hardness. Such condition affected productivity as worn cutting tool detrimental to the machined surface and the production need to stop to replace the cutting tool. In the recent advancement of machine tool technology, a new type of steel already applied for automotive structure. This steel, named as 22MnB5 Boron Steel, produced by the hot stamping process where the sheet metals were formed and heat treated inside metal stamping dies. 22MnB5 Boron Steel categorized as ultra-high strength steel with 1500 MPa tensile strength and 80 HRC hardness. Such properties resembled almost similar to HSS which make them potential to be applied as cutting tool. The purpose of this study is to investigate the capability of 22MnB5 Boron Steel as a cutting tool in machining aluminium alloy. Initial part of study involved with analysis on the physical and mechanical properties of 22MnB5 in terms of hardness, density, tensile strength, surface appearance and coefficient of friction. The second part covers machining trials of 22MnB5 Boron steel on Al 6061 Aluminum Alloy using various condition and parameters. Lastly the third parts cover assessment of failure modes and wear mechanism of 22MnB5. The results show that combination of high hardness of 70HRC, density of 7.841 g/cm3 and tensile strength of 1500 MPa facilitate strong edge of 22MnB5 to machine Al 6061 smoothly. 22MnB5 capable to machine Al 6061 Aluminum Alloy in wet condition up to 861 s at 200 m/min, 0.1 mm/rev and 0.5 mm cutting speed, feed rate and depth of cut respectively. The wear mechanism showed up as fragmented debris and built up layer dominated the flank and crater surfaces with abrasive and adhesive effects. This study built better understanding of 22MnB5 characterization in operation that involved with friction, tribology and machining. Finding from this study could also benefit the industries in terms of selection of cutting tools that capable to machine product with sustainable manufacturing approach.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohd Rashid, Mohd Fairuz
author_facet	Mohd Rashid, Mohd Fairuz
author_sort	Mohd Rashid, Mohd Fairuz
title	Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
title_short	Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
title_full	Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
title_fullStr	Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
title_full_unstemmed	Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy
title_sort	machining performance of 22mnb5 boron steel cutting tool with al 6061 aluminium alloy
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2021
url	http://eprints.utem.edu.my/id/eprint/26084/1/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf http://eprints.utem.edu.my/id/eprint/26084/2/Machining%20performance%20of%2022MnB5%20Boron%20steel%20cutting%20tool%20with%20Al%206061%20Aluminium%20Alloy.pdf
_version_	1776103134621335552

Machining performance of 22MnB5 Boron steel cutting tool with Al 6061 Aluminium Alloy

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