Effects of machining parameters when reaming aluminium–silicon (SAE 322) alloy

This paper evaluates the dimensional stability (diameter, roundness and cylindricity) and surface roughness of reamed cylindrical holes using K10 cemented carbide welded blade reamers on aluminium–silicon hypoeutectic (SAE 322) cast alloy at various cutting conditions in order to optimise the cutting process. The following parameters were individually varied: depth of cut, cutting speed, feed rate, helix angle, number of blades, margin size and rake face finishing of reamers. Power consumption during the reaming operation was also recorded. The test results show that satisfactory hole quality can be achieved during reaming by employing smaller depths of cut, lower cutting speeds, higher feed rates as well as straight-flute reamers with many blades [Experimental Methods for Engineers, 3rd Edition, McGraw-Hill, New York, 1978] and small margins. Reaming at higher feed conditions improves the accuracy of holes produced at the expense of an increase in power consumption and deterioration in the surface finish generated. The use of reamers with many blades can improve the accuracy, surface finish and roundness of holes produced at the cost of poor cylindricity and higher power consumption during machining.