The master's thesis deals with dry trochoidal milling of aluminum alloys. Due to economic, ecological, health and technological reasons in the use of lubricants, we decided to try to reduce the use of these products by using dry trochoidal milling technology.
In order to successfully implement a new processing strategy, we have upgraded the whole approach. We have presented the materials, tools and CAM strategy, we have also performed the optimization of key cutting parameters with industrial Taguchi statistical method. On the real product from the automotive industry, we have made a comparison of trochoidal and conventional milling and showed the effectiveness of both methods. The trochoidal method has proven to be much more effective. There was also made a comparison between dry and wet trochoidal milling with tools of three different manufacturers. Tests have shown that the wear rate is greater for the tools used during dry treatment. Moreover, we have also noticed that some tools are more susceptible to the appearance of adhesion (gluing). We believe that the reason is the uncoated surface and poorly designed cutting geometry of the tool. One of the tools during dry tests was fared satisfactorily, which indicates that the choice of the appropriate tool is crucial. In spite of the fact that due to the greater wear of the tools, a smaller number of pieces is treated, dry processing is still more economical in our estimation, since the cost of the additional tool is much lower than the cost of using the CLF. As a result, the final price of the product is also reduced.
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