Exploring the Sustainable Impact of Tool Evaluation and Operational Efficiency on Machining Aluminum Alloy AA6061-T6

The research elaborated focuses on the tool evolution and operational efficiency in relation to machining Aluminum Alloy AA6061-T6. AIDS, therefore, leads to sustainable operations in manufacturing. Efforts are also made to minimize the amounts of waste and energy consumed, and tool efficiency in operational performance is improved due to this study. On the other hand, this work discusses the dual relationship of tool evaluation and operational efficiency during the machining of Aluminum Alloy AA6061-T6, focusing on sustainable manufacturing. The research chiefly dwells on the factors aimed at reducing the effects while enhancing the utilisation of the resource by the proper adjustment of the tool system as well as the operational systems. The tool used had a nose radius featuring a thickness of 0.8 mm and a rounded corner with a radius of 0.4. The machining tests were conducted using six different cutting speeds. The tool wear was considered by taking into due regard crater wear, flank wear, and edge chipping to enable the assessment of the variation of tool wear over the operation period. On the other hand, the performance of the tool was assessed based on the evaluation of cutting force, machined surface roughness, and chip formation. The results have shown that tool wear increases when operating at elevated speeds and feed rates, that is increasing almost twice that of normal machining conditions. On the plus side, there is some improvement in surface finish and chip quality. Present research underlines the need for proper defining of cutting parameters in view of achieving an optimal tool utilization quality regarding the machined Aluminum Alloy AA6061-T6.