Evaluation of the drilling process in 6061-T6 Al-Mg-Si alloys using AISI M-35 diamond-like carbon coated high-speed steel drill

The diverse mechanical properties found in aluminum alloys make them an ideal option for various industrial sectors. The machining process still presents challenges, especially adhesion. The common way to deal with high machining temperatures is to use cutting fluid. However, due to environmental and operator health issues, alternatives to these products have been sought. One possibility to reduce these problems is by using film-coated tools such as Diamond-Like Carbon (DLC), which provides high hardness and a low coefficient of friction, and whose good performance is related to its adhesion on the tool surface. The present work investigated the performance of ground high-speed steel drills coated with DLC in the drilling process of 6061-T6 Al-Mg-Si alloy. Furthermore, the material was characterized and an analysis of the macro and microgeometric errors of the alloy was carried out. The results obtained from the analysis of the machined alloy were, for the most part, uniform. An increase in tool life was observed, which was able to machine 1000 dry holes.