Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions.

The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses.