Effect of alkoxide film on chip morphology under electrostatic catalysis in cutting 1060 aluminum alloy

To address the challenges of large plastic deformation, tool adhesion, and built-up edge formation during aluminum alloy cutting, a novel approach using charged alcohol-containing cutting fluid in the machining of aluminum alloy is proposed. On the basis of investigating the mechanism of charging on the formation of chemical reaction films by 1,2-propanediol on the surface of 1060 aluminum alloy, orthogonal cutting experiments were carried out. It was found that charging enhances the chemical activity of alcohol-containing cutting fluids on the surface of aluminum alloys, leading to increased surface hardness and facilitating the plastic-brittle transition on the surface of the material. Under the conditions of static electricity and 1,2-propanediol-containing cutting fluid, the serrated degree of aluminum alloy chips increased, while the chip thickness ratio and cutting force decreased. Additionally, the maximum height of the chip free surface profile increased. The results of this research will offer a fresh concept and approach for achieving high-efficiency and environmentally friendly cutting of aluminum alloys.