Effect on Formations of Built-up Edge and Built-up Layer, Surface Roughness of Cutting Speed and Rake Angle in the Machining of Aluminum Alloys

In this study, the effects on surface roughness of cutting parameters (tool rake angle and cutting speed) were investigated in the machining of AA 2011 and AA 7075 aluminum alloys. The interactions between the cutting parameters and Build-up edge (BUE), Built-up layer (BUL) formed on tool rake face were also evaluated the same machining processes. In the machining tests, the testing apparatus which allowing chip removal by giving rake angle in both positive and negative side to the cutting tool was used. The average surface roughness (Ra) values for both alloys were considerably high in especially small values of rake angle (0 degrees and -5 degrees) for AA 7075 alloy, while Ra values for both alloys have been low in larger values of rake angle (15 degrees ve 20 degrees). The effect of the formations BUE and BUL of the rake angle and the alloy content were evaluated by examining uncoated carbide cutting tools used in cutting experiments with metallographic methods (SEM and EDS analysis). Consequently, the formation of BUE and BUL for AA 7075 alloy has been greater than that of AA 2011 alloy.