Numerical Analysis of Cutting Modes in High-Speed Machining of Aluminum Alloys with PCD and CBN Tool Inserts

In manufacturing industries, high-speed machining of aluminum alloys is highly recommended for achieving better productivity in terms of cutting force reduction and improved surface finish. Even though an overwhelming number of process parameters affect the high-speed machining operations, tool material is considered to be the most predominant factor in determining the machining performance. Hence, in the present work, experimental and simulation analyses are carried out for understanding the effect of different tool materials in high-speed machining of aluminum alloy. Formation of dead metal zone is taken as the fundamental criterion for analyzing the discrepancy in cutting forces, and the same is discussed in detail in the present paper.