Cutting force analysis in reaming of ZL102 aluminium cast alloys by PCD reamer.

The cutting forces are studied for the reaming of casting aluminium alloy ZL102 (ZAlSi12) using a four-flute PCD reamer on DMG DMU 50 linear five-axis CNC machine. Kistler Dynamometer is used to measure the cutting force ( X-, Y- and Z-axes) and torque. Three-coordinate measuring machine is used for measuring cylindricity of machined hole. The cutting force signatures are diagnosed by using Fast Fourier Transform (FFT) algorithm. FFT analysis suggests that fundamental frequency is only determined by cutting speed. The frequency for the thrust signal of cutting force is zero which illustrates that the thrust is constant when cutting speed and cutting feed are fixed. The relationship between the cutting force and cutting parameter are investigated by using FFT filtering. High value of cutting feed and the low cutting speed provide the higher thrust. The optimized machining parameters are provided relative to cutting force ( Fx and Fy) and the cylindricity of reamed holes. [ABSTRACT FROM AUTHOR]