Surface integrity and tool wear mechanism of 7050-T7451 aluminum alloy under dry cutting

In this paper, we present an experimental study on the effects of cutting parameters on the surface integrity and tool wear mechanism of AA7050-T7451 aluminum alloy under dry cutting. We perform single-factor cutting tests and finite element simulations to observe how cutting parameters affect cutting force, cutting temperature, workpiece surface morphology, work hardening, residual stress, and tool wear. The results show that the three cutting factors significantly affect cutting force, cutting temperature, and workpiece surface roughness. Higher cutting speeds and lower feed rates can improve surface roughness, whereas cutting depth does not make much difference to surface roughness. Work hardening first increases and then decreases with increasing cutting speed and feed rate, whereas work hardening degree is negatively correlated to cutting depth. Residual stress occurs as a ladle with changing cutting parameters. Cutting speed and feed rate affect residual stress considerably. The maximum residual compressive stress layer is 120 mu m deep, and the subsurface maximum residual tensile stress layer is 300 mu m deep. Tool wear typically involves abrasive wear under low speed, adhesive wear under medium speed, and oxidation wear under high speed.

Automated summary

The cutting parameters significantly affect the surface roughness, work hardening, and residual stress of AA7050-T7451 aluminum alloy. Higher cutting speeds and lower feed rates can improve surface roughness, while cutting depth has little effect on surface roughness. Residual stress is closely related to changing cutting parameters.