Turning of Al 7075-T6 aerospace alloy under different sustainable metalworking fluid strategies by coated carbide tools

ABSTRACT We primarily need to reduce the consumption of metalworking fluid to ensure sustainable and eco-friendly machining of aerospace alloys. The present study was planned to determine the efficiency of various eco-friendly metalworking fluid strategies for the sustainable turning of aerospace aluminium alloy (Al7075-T6) coated carbide tools under different eco-friendly metalworking fluid strategies namely dry machining, minimum quantity lubrication (MQL), Ranque-Hilsch vortex tube (RHVT), and compressed air. Machining performance was investigated in terms of micro-hardness, tool tip temperature, tool wear, cutting forces, work surface roughness, chip morphology, and energy consumed. Results manifested that MQL and tool coatings can significantly lower tool tip temperature by up to 16%, tool wear by up to 102–106%, average cutting forces by 17–21%, and surface roughness reduced from 11–21% as compared to dry conditions. Abbreviations: BUE, built-up edge; CVD, chemical vapour deposition; CrN, chromium nitride; DCR, disposed chip ratio; DLC, diamond like carbon; DSPR, disposal scrap part ratio; EDS, energy dispersive X-ray spectroscopy; MF, metalworking fluid; MoS2, molybdenum disulphide; MQL minimum quantity lubrication; PVD, physical vapour deposition; RHVT, Ranque-hilsch vortex tube; RPSR, recycled part scrap ratio; RSPR, remanufacturing scrap part ratio; SEM, scanning electron microscopy; SDSS, super duplex stainless steel; TiAlN, titanium aluminium nitride