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New milling methodology for sealing planes in AlSi9Cu3(Fe) alloy machined with PCD tool

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Abstract

The use of self-moulding resins in industry makes it necessary to specify minimum values for the surface roughness parameters in order to avoid fluid leaks between the sealing planes. To meet this requirement, new tool classes, machining parameters, and methodologies are being used. Thus, this work applies a new methodology for plane milling, with the objective of increasing the tightness of the union with adhesive. The investigation was based on experimental planning techniques for the behaviour of the surface roughness in machining of AlSi9Cu3 alloy by frontal milling with refrigeration, carried out in a transmission union support, in high-speed cutting (HSC) machining centres. The evaluated parameters were the cutting speed (Vc) between 1250 m/min and 2250 m/min, and the feed per tooth (fz) between 0.050 mm/tooth and 0.100 mm/tooth. Two cutters with ten polycrystalline diamond (PCD) inserts were used to mill the sealing surface, with one of the cutters having eight cutting inserts and two scratching inserts. The cutoff considered was 2.5 mm and the statistical technique of design of experiment (DOE) was used to evaluate the experimental results. The optimum roughness values, achieved with the cutter with scratching inserts, were a Vc of 1250 m/min and fz of 0.05 mm/tooth.

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Acknowledgements

The authors are grateful to CNPQ, CAPES, FAPEMIG, Fiat Chrysler Automobiles (FCA), and Pontifical Catholic University of Minas Gerais (PUC-MG) for technical support.

Funding

This study was financed in part by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior—Brazil (CAPES)—Finance Code 001.

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Authors and Affiliations

  1. Mechanical Engineering Department, Pontifícia Universidade Católica de Minas Gerais – PUC Minas, Avenida Dom José Gaspar, 500 – Campus Coração Eucarístico – CEP, Belo Horizonte, MG, 30545-901, Brazil

    Gilmar Cordeiro da Silva, Querlem Martins Saraiva, José Rubens Gonçalves Carneiro & Izabela Ângela Santos

  2. Tool Engineering - Engines And Transmissions Unit, Stellantis Fiat Chrysler Automobiles, Av. Contorno, no. 3455 - Bairro Paulo Camilo – CEP, Betim, MG, 32669-900, Brazil

    Anderson Silva José

Authors
  1. Gilmar Cordeiro da Silva
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  2. Querlem Martins Saraiva
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  3. José Rubens Gonçalves Carneiro
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  4. Izabela Ângela Santos
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  5. Anderson Silva José
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Contributions

Gilmar Cordeiro da Silva: conceptualization, project supervision, and writing; Querlem Martins Saraiva: conceptualization, experiments, writing; José Rubens Gonçalves Carneiro: conceptualization; Izabela Angela Santos: data analysis, writing; Anderson Silva José: experiments

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Correspondence to Gilmar Cordeiro da Silva.

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da Silva, G.C., Saraiva, Q.M., Carneiro, J.R.G. et al. New milling methodology for sealing planes in AlSi9Cu3(Fe) alloy machined with PCD tool. Int J Adv Manuf Technol 113, 3211–3223 (2021). https://doi.org/10.1007/s00170-021-06843-8

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