STUDY ON THE INFLUENCE OF CUTTING FACTORS  ON THE CHIP SHRINKAGE COEFFICIENT IN THE TURNING  OF AA6061 ALUMINUM ALLOY

Hoa-Thi Pham; Thuc- Dang Phan

Hoa-Thi Pham Hung Yen University of Technology and Education
Thuc- Dang Phan Bacninh College of Industry

Keywords: chip shrinkage coefficient, AA6061 aluminum alloy, Taguchi

Abstract

This study investigates the influence of cutting parameters on the chip shrinkage coefficient (K) during the turning of AA6061 aluminum alloy using a Taguchi experimental design. Four machining parameters— tool nose radius (r), cutting speed (V), feed rate (f), and depth of cut (t)—were evaluated at three levels, and their effects were analyzed through signal-to-noise (S/N) ratio, analysis of means, and interaction plots. The results indicate that feed rate is the dominant factor affecting K (chip shrinkage coefficient), followed by depth of cut, whereas tool nose radius and cutting speed have relatively minor influences. A significant interaction between feed rate and depth of cut demonstrates that chip shrinkage is primarily governed by uncut chip geometry, which intensifies plastic deformation and shear in the primary deformation zone. The optimum cutting conditions for minimizing K were identified as r = 0.4 mm, V = 150 m/min, f = 0.08 mm/rev, and t = 0.5 mm. The novelty of this work lies in providing a systematic quantitative assessment of both the individual and interactive effects of machining parameters on the chip shrinkage coefficient, revealing the dominant role of uncut chip geometry in chip formation. These findings offer new insights into chip deformation mechanisms and provide practical guidelines for optimizing the turning performance of AA6061 aluminum alloy.

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