Study on chip formation when machining aluminum alloy 7075-T6 with carbide tools under high-speed machining

Abstract

This paper discusses the effect of cutting parameters on the chip formation when machining Aluminum Alloy 7075-T6 with carbide tools under high-speed machining. The cutting condition applied in this study were dry and near dry conditions. Full factorial design with 3 factors and 2 level was used. The cutting speed, feed rate and axial depth of cut used are 500 m/min and 600 m/min, 0.12 mm/tooth and 0.15 mm/tooth and 1.40 mm and 1.70 mm respectively. The near dry cutting is also known as Minimum Quantity of Lubricant (MQL). The flow rate applied was 100 mL/H. This experiment shows that the size of chip much depends on the feed rate and depth of cut. Smaller chip was observed at lower feed rate and lower depth of cut. Cutting speed has no significant impact on the size of chip. Chips produced under MQL machining have less burn marks. This is a strong evidence that the MQL can reduce the heat generated at the cutting zone.