An experimental investigation of micro-machinability of aluminum alloy 2024 using Ti(C7N3)-based cermet micro end-mill tools

In the present work, a Ti(C7N3)-based cermet micro end-milling tool was developed. Thereafter, the cutting characteristics and tool performance were investigated during machining of aluminum alloy 2024. The burr formation, tool wear and chip information were analyzed at various cutting parameters. Further, failure mechanism of Ti(C7N3)-based cermet micro end-mill tools were thoroughly discussed. The results indicated that the burr was initiated after six minutes of micro milling using the WC micro end-mill tool but after thirteen minutes of micro milling using the Ti(C7N3)-based cermet micro end-mill tool. The main wear mechanisms of the Ti(C7N3)-based cermet micro end-mill tool were micro-crack initiation and crack propagation resulting in tool failure. Chip information was also discussed in combination with uncut chip thickness. However, different properties and characteristics of Ti(C7N3)-based cermet indicate its superiority over other commonly used tool materials especially WC.