Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

Abstract

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.