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Effect of reinforced particles on the machinability of Al alloy under MQL, cryogenic, and hybrid lubrication

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Abstract

Aluminum-based metal matrix composites (MMCs) offer a high strength-to-weight ratio with excellent abrasion resistance, finding vast applications in aerospace industries. However, machining these materials is difficult due to the high hardness and wear resistance resulting in a shortened tool life. In this context, Al 7075 hybrid MMC was fabricated with reinforcing elements of TiO2 and Gr (graphite) particles. Furthermore, the machinability of newly fabricated HMMC was investigated under dry, MQL with vegetable oil, cryogenic CO2, and hybrid (MQL + CO2) cutting environments. As per the originality of this work, no studies compared the machinability of Al 7075 HMMC under selected cutting environments. With the reinforcement in Al alloy, the higher cutting forces and deteriorated surface finish were observed with dry milling. The abrasion wear mechanism will dominate under all cutting environments with various feeds and speeds. The combination of MQL + CO2 cutting environments was found to be more effective in terms of cutting forces, with a reduction of 39 to 28% compared to other selected cutting environments. The surface roughness was reduced by 18%, 15%, and 13% with favorable chip generation under MQL + CO2 than that of dry, MQL, and CO2 cooling modes. Additionally, MQL + CO2 showed enhanced tool life with a significant reduction in tool wear.

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Authors and Affiliations

  1. School of Mechanical Engineering, Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, Shandong, China

    Vinothkumar Sivalingam, Haochen Liu, Mingjian Sun & Guo Kai

  2. Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences (SIMATS), Chennai, 602105, India

    Vinothkumar Sivalingam

  3. Tribology and Machine Dynamics Laboratory, Department of Mechanical Engineering, Design, and Manufacturing, Indian Institute of Information Technology, Jabalpur, Madhya Pradesh, 482005, India

    Saurabh Tiwari

  4. Department of Mechanical Engineering, Faculty of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur, Tamil Nadu, India

    Poongavanam Ganesh Kumar

  5. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St, 45-758, Opole, Poland

    Munish Kumar Gupta

  6. Department of Mechanical Engineering, Graphic Era (Deemed to Be University), Dehradun, India

    Munish Kumar Gupta

  7. Advanced Manufacturing Lab (AML), School of Engineering, University of Guelph, Guelph, Ontario, Canada

    Abdelkrem Eltaggaz

  8. Department of Mechanical Engineering, School of Engineering, Mohan Babu University, 517 102, Tirupati, India

    Ramesh Raju

Authors
  1. Vinothkumar Sivalingam
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  2. Haochen Liu
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  3. Saurabh Tiwari
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  4. Poongavanam Ganesh Kumar
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  5. Mingjian Sun
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  6. Guo Kai
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Correspondence to Vinothkumar Sivalingam or Munish Kumar Gupta.

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Sivalingam, V., Liu, H., Tiwari, S. et al. Effect of reinforced particles on the machinability of Al alloy under MQL, cryogenic, and hybrid lubrication. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13534-7

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