The effects of hard particles on the surface quality when micro-cutting aluminum 6061 T6

Studies of micro-cutting have so far largely been carried out on single-phase materials. Due to the size effect, the workpiece material microstructure can have a significant influence on the cutting force, chip formation and surface quality. Previous investigations have shown that hard particles in materials such as aluminum alloy can play a significant role in the generation of defects such as cracks and voids on the work surface. This paper will examine the extent of the problem during the micro-cutting of Al6061 T6 and propose how it can be mitigated.