Size effects in ultraprecision machining of aluminum alloys: Conventional AA6061-T6 and RSA 6061-T6

The metallurgical modification in non-ferrous metal alloys is carried out to adapt not only physical or mechanical properties their applications, but also improve machinability. In the case of aluminum for optical reduction grain size an alteration aimed at adapting dimensions microstructure dimensional scale used machining conditions. cutting section are often much smaller than average size, which causes anisotropic effects on both material removal mechanism and surface integrity. objective this study compare effect material's microstructure, case, mechanism, energy dissipation generation involved ultraprecision diamond turning alloy 6061-T6 using micrometric submicrometric Cutting forces results showed that below feedrate 10 ?m/rev there a reversal forces, thrust force becomes greater main force. specific reaches values one order magnitude higher conventional when with nanometer range undeformed chip thickness. impurities, hard inclusions, void formation anisotropy will be assessed discussed by explicating influence finish nanoscale level. Based observations profilometry scanning electron micrographs, machined surfaces chips removed were aforementioned factors identified. Under nominal thickness 286 nm does show parallel groove marks left tool. As decreases, friction coefficient high, leading due rubbing action tool-chip interface move downward edge portion. Below value attributed burnishing round part tool portion adjacent flank face. It was observed process obtain each type play important role performance formation. cross sectional area 50 ?m2 particles dragged surface. This roughness increase.