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Clean machining is gaining ground as one of the crucial issues in future manufacturing. Many machining industries are looking for alternative solutions to wet machining because of the costs of the latter, including environmental costs, as well as its impact on occupational health and safety. Dry machining is being proposed, but in most conditions, the cutting tool wears out quicker, leading to part quality deterioration and increased machining costs. Minimum quantity lubrication (MQL) machining is also proposed to maintain a reasonable tool life and limited cost, as compared to the situation with flood or wet machining. Both the MQL and dry machining methods, however, are susceptible to the generation of aerosols containing metallic particles that can be detrimental to occupational health and safety. Minimizing particle emissions is of prime importance since these can have serious consequences on the operator's health. They have been seen to be at a minimum at two specific cutting ranges. In this study, investigations are done to examine the effect of lubrication (dry and MQL) during the turning of the 7075-T6 aluminum alloy. The performance indexes studied are the surface roughness, the chip thickness, and aerosol generation. [ABSTRACT FROM AUTHOR]

Aluminum alloys are widely used in several applications. Cast alloys are usually considered to be brittle materials leading to short chip formation during machining. Although they can be produced near net shapes, products made of these alloys very often require some machining. The purpose of this study is to evaluate the machinability ofA319andA356underT0andT6conditions. The machinability was assessed during the dry drilling machining process, with the machinability indexes including the chip form, chip breakability, and the cutting forces. It was found thatA319andA356exhibit different machinability behaviors, especially under the T6-condition in terms of force requirements, chip breakability, and chip segmentation. The chip grain size obtained by X-ray diffraction techniques was also studied and correlated to the machining conditions. It was also found that both the microstructure of the workpiece materials and the machining conditions significantly affect the chip formation mechanism, and so the machining parameters could therefore be selected to promote a chip form that is easily manageable in production. [ABSTRACT FROM PUBLISHER]

In the present study, an attempt has been carried out to investigate the effect of cutting fluid applications including dry, mist and flood drilling on the part quality during drilling of 6061-T6 aluminum alloy. The part quality criteria include the surface finish and burr size. A multi-factorial experimental design (DOE) and analysis was used. It has also been found that dry machining and mist machining can produce parts with quality comparable to those obtained in wet machining when using the optimal cutting conditions. [ABSTRACT FROM AUTHOR]