مهدي نظرپوربراگوري

Aluminum alloy 7075 is extensively used in various industrial applications due to its high specific strength an‎d favorable mechanical properties; however, its machining is often challenged by chip adhesion, elevated cutting temperature, an‎d degradation of surface quality. To address these issues, the use of textured cutting tools an‎d advanced lubrication techniques has gained increasing attention. This study investigates the machining performance of uncoated carbide tools with different surface textures under various lubrication conditions during the turning of aluminum alloy 7075. Three tool configurations, including a non-textured tool, a grooved textured tool, an‎d a hybrid grooved–holed textured tool, were eva‎luated under four lubrication conditions: dry cutting, solid lubrication, minimum quantity lubrication (MQL), an‎d combined MQL–solid lubrication. The feed rate was selec‎ted as the sole variable machining parameter an‎d was examined at three levels of 0.08, 0.16, an‎d 0.24 mm/rev, while the cutting speed an‎d depth of cut were maintained constant. Surface roughness, cutting zone temperature, an‎d chip morphology were considered as the primary response variables. The results demonstrated that increasing the feed rate led to higher surface roughness; however, the application of textured tools in combination with effective lubrication significantly alleviated this effect. The hybrid grooved–holed textured tool combined with MQL–solid lubrication exhibited the best performance, achieving an approximately 34% reduction in surface roughness compared to dry cutting. Moreover, MQL showed the highest capability in controlling the cutting temperature, resulting in a maximum temperature reduction of 53%. Chip morphology analysis revealed the formation of shorter an‎d more segmented chips under textured tool an‎d MQL-based lubrication conditions, indicating improved chip breakability an‎d enhanced machining performance.

بافت ابزار , روانكار جامد , زبري سطح , دماي ماشينكاري , آلومينيوم 7075

Tool texture , Solid lubricant , Surface roughness , Machining temperature , 7075 Aluminum

Mahdi Nazarpour Bragouri

Behnam Davoodi