Review of improvement of machinability and surface integrity in machining on aluminum alloys

Abstract

Aluminum alloys are widely used in many industries, including aerospace, automotive, civil, and electrical engineering. When compared to pure aluminum, most aluminum alloys have lower electrical and thermal conductivity, corrosion resistance, and weldability, as well as a low density and specific gravity. At the same time, the properties of aluminum alloys vary significantly depending on the group, which has a significant impact on their machinability. This review article is focused on the study of machining characteristics of aluminum alloys, such as machinability, surface integrity, tool wear and tool life, material removal rate (MRR), and chip morphology. The directions of increasing machinability by controlling cutting parameters, cutting environment, such as dry machining, conventional cooling systems, minimum quantity of lubricant (MQL), cryogenic lubrication (CL), with tool geometry, and textured tools, are also considered; tool materials include coating, vibration, thermally, and hybrid assisted machining. The article discusses the main types of machining, namely, turning, milling, drilling, and grinding. It shows ways to increase the machinability of machining on aluminum alloys, as well as the advantages and disadvantages. From the literature, it can be concluded that tool wear when machining aluminum alloys is 30–40% lower than when machining steel alloys due to their higher ductility and lower strength. Surface integrity, affected by the cutting parameters and cutting temperatures — which can reach between 200 and 400 °C — can vary by up to 15% in hardness and 20% in surface roughness. Cutting tool characteristics can enhance surface finish by up to 25% and extend tool life, reducing edge formation by up to 30%. Chip morphology, influenced by factors such as cutting parameters and tool material, can improve tool life by up to 35%. Vibration techniques can reduce thermal effects and improve surface finish by up to 40%, reducing cutting forces by around 30%.

Multiparameter signal-to-noise ratio optimization for end milling cutting conditions of aluminium alloy 5083

“…The current work is an optimization study of cutting conditions during dry end milling of AA5083, where the optimized geometry of the two-flute cutter is manufactured by a grinding 5-axis machine, as described in detail in Kechagias et al [17], and then the radial cutting depth, feed per tooth, and speed were tested in different dry cutting conditions. Note here that, in the literature, the majority of the research works utilized cutters from the market and not laboratorymade [35][36][37][38][39]. Therefore, the cutter geometry details were designed and optimized for the specified AA5083 alloy.…”

Study the effects of machining parameters on the surface characteristics of aluminum-magnesium alloy with different nose radiuses

“…Surface roughness, which is used to determine and evaluate the quality of a product, is one of the major quality attributes of a turned product [8]. a machined product's surface roughness may have an impact on several of its functional characteristics, including contact-induced surface friction, wear, light reflection, transmission, the capacity to distribute and hold lubricant, coating, and fatigue resistance [9] [10]. Surface roughness is one of the crucial quality factors in turning operations as a result [11] [12].…”

Parametric analysis, modeling and optimization of the process parameters in electric discharge machining of aluminium metal matrix composite

“…MMCs may produce discontinuous and difficult-to-break chips during conventional machining, leading to chip jamming, tool clogging, and poor chip evacuation. Inadequate chip control can result in surface defects, tool damage, and decreased machining efficiency [15][16][17]. These materials have therefore been machined using advanced machining processes.…”