Machinability characteristics of lead free-silicon brass alloys as correlated with microstructure and mechanical properties

Abstract The aim of this work is to evaluate the machinability of Pb-free brasses with Si from 1% to 4 wt%, which were prepared using Cu 60/Zn 40 and Cu 80/Si 20 Pb-free master alloys. Machinability of the investigated alloys is tested based on cutting force, tool wear, surface roughness, and chip type. In the 1 wt% Si alloy, which exhibits maximum strength, the maximum cutting force is measured and undesirable continuous chip type is produced, while tool wear and machined surface roughness have the lowest values. Increasing the silicon content from 1% to 4%, results in increasing the tool wear by 140%, machined surface roughness by 25%, while the chip type changed from continuous to discontinuous type, and the cutting force was reduced by 50%. Machinability results are correlated with the alloy mechanical properties and with the phases present in the microstructure.