Environmentally Friendly Approaches Assisted Machining of Aluminum Alloy 7075-T6 for Automotive Applications: A Review

Zainol, Azreen; Malaysia, , Taman Shamelin Perkasa, . Miles Cheras, Kuala Lumpur,; Yazid, Mohd Faizun Mohamad

doi:10.30880/ijie.2019.11.06.003

Cited by 7 publications

(2 citation statements)

References 33 publications

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“…Lightweight manufacturing in the automotive industry is one of the topics at the forefront of research activities for two main reasons: the reduction of emissions and the positive effect on road safety [1,2]. In this regard, ultra-high-strength aluminium alloys are in high demand in the automotive and aerospace industries, where weight savings are critical.…”

Section: Introductionmentioning

confidence: 99%

Super-Hard DLC Coatings as an Alternative to Polycrystalline Diamond for Cutting Tools: Predictive Analysis of Aluminium Alloy Surface Quality

Ramírez

Castro²,

Prat

et al. 2022

Lubricants

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The use of lightweight materials, such as ultra-high-strength aluminium alloys, is in high demand in the automotive and aerospace industries where weight savings are critical. The tool materials used for high-speed cutting of these aluminium alloys are subjected to severe conditions that promote premature failure of cutting tools. The application of polycrystalline diamond (PCD) coatings provides cutting tools with increased mechanical and thermal fatigue resistance and improved tribological performance. Despite these good properties, their high cost remains a major limitation in this sector. Super-hard Diamond-Like Carbon (DLC) coatings offer a technologically and economically feasible alternative to PCD-coated tools for cutting and machining non-ferrous materials. In this paper, the machining performance of coated and un-coated hard metal inserts in the turning of 7075 aluminium alloy has been explored. The surface quality of machined parts, the cutting tool wear resistance and the vibrations generated during turning of un-coated, PCD and super-hard thin DLC coatings on tungsten carbide inserts were compared. The results obtained demonstrate that DLC coatings are a potentially interesting alternative to PCD coatings for machining ultra-high-strength aluminium alloys, where surface component finish is a key factor.

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Section: Introductionmentioning

confidence: 99%

Super-Hard DLC Coatings as an Alternative to Polycrystalline Diamond for Cutting Tools: Predictive Analysis of Aluminium Alloy Surface Quality

Ramírez

Castro²,

Prat

et al. 2022

Lubricants

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show abstract

“…A popular aluminum alloy material for machining in the various industrial sectors, particularly aerospace, is a 7000 series group [15]. Aluminum alloy 7075-T6 has been one of the popular materials in the 7000 series due to possessing exceptional mechanical behavior and combined elements such as zinc, magnesium, and copper to improvise their strength [16], [17].…”

Section: Introductionmentioning

confidence: 99%

Effectiveness of Near Dry Machining on Tool Performance in Bull Nose Milling of Aluminum Alloy 7075 T6

Yazid,

Zainol

2019

IJEAT

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The paper investigated the effectiveness of near-dry machining also known as minimum quantity lubrication (MQL) on tool wear when aluminum alloy 7075-T6 was milled using bull nose carbide insert. The foregoing study found that the high tool wear was occurred in machining aluminum alloy 7075-T6 with uncoated carbide under dry machining. Due to that, dry machining was performed to examine its result with MQL. Different values of cutting parameter selected were cutting speed of 500 and 600 m/min, the feed rate of 0.12 and 0.15 mm/tooth, and axial depth of cut of 1.40 and 1.70 mm. 100 mL/h was set as MQL flow rate. Eight samples were performed on five axes milling machine according to a full factorial design. The tool wear was examined and measured progressively at every time interval using an optical microscope. From the analysis, MQL 100 mL/h at 500 m/min, 0.12 mm/tooth, and 1.40 mm was found to be better than dry machining. The adhesion wear mechanism was observed at both machining conditions. Near-dry machining with appropriate flow rate and machining parameters has the potential to contribute to long-term environmental friendly machining in line with the industrial revolution phase.

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Prediction of crater tool wear using artificial intelligence models in 7075 Al alloy machining

Gabsi

2023

Int J Interact Des Manuf

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Environmentally Friendly Approaches Assisted Machining of Aluminum Alloy 7075-T6 for Automotive Applications: A Review

Cited by 7 publications

References 33 publications

Super-Hard DLC Coatings as an Alternative to Polycrystalline Diamond for Cutting Tools: Predictive Analysis of Aluminium Alloy Surface Quality

Super-Hard DLC Coatings as an Alternative to Polycrystalline Diamond for Cutting Tools: Predictive Analysis of Aluminium Alloy Surface Quality

Effectiveness of Near Dry Machining on Tool Performance in Bull Nose Milling of Aluminum Alloy 7075 T6

Prediction of crater tool wear using artificial intelligence models in 7075 Al alloy machining

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