Experimental Investigation and Optimizing of Turning Parameters for Machining of Al7075-T6 Aerospace Alloy for Reducing the Tool Wear and Surface Roughness.

The current work presents an approach for the optimization of machining parameters on the turning of Al7075-T6 aerospace alloy. The alloy was turned on a lathe machine equipped with four different metalworking fluid (MF) setups: minimum quantity lubrication (MQL), Ranque–Hilsch vortex tube (RHVT), compressed air, and dry cutting using coated carbide tools. Taguchi technique was considered for the design of the L16 experimental array with three variable factors and four levels, and S/N ratios were obtained. The turning parameters feed rate and cutting speed are optimized in the experiment, taking into account responses such as surface roughness and tool wear. ANOVA determined the significant parameters that majorly influenced the responses. The results demonstrated that the condition of machining (<99% probability) was the most influential parameter followed by cutting speed (<95% probability) which affects the surface roughness and tool wear. Moreover, turning with MQL at a low cutting speed represented the optimum machining setup for reducing surface roughness and tool wear of this alloy. It was due to the fact that MQL decreases the friction between the tool and the workpiece which reduce the mechanical and thermal stresses on the cutting tool, resulting in lessened tool flank wear and effectively improving the surface quality. [ABSTRACT FROM AUTHOR]