Experimental investigation and optimization of cutting parameters in dry and wet machining of aluminum alloy 5083 in order to remove cutting fluid

Abstract

Abstract Many problems such as health and environment issues are identified with the use of flood cutting fluids in machining processes. Considerable attention has been given to reduce or completely omit the cutting fluids, and meet the demands for environment-friendly cutting processes. In this study, the effects of cutting speed and undeformed chip thickness on cutting and feed force components and tool tip temperature were experimentally investigated in order to remove cutting fluid. AA5083-O wrought alloy with a high Mg content (4.5%) was machined in dry and wet machining conditions utilizing coated carbide tool. Two-factor (cutting speed and undeformed chip thickness) and five-level fractional experiment designs completed with a statistical analysis of variance (ANOVA) were performed. Mathematical models for cutting and feed force components and tool tip temperature were developed using the Response Surface Methodology (RSM). Results show that the output variables are significantly affected by the undeformed chip thickness. On the other hand, in the high cutting speed and low undeformed chip thickness, AA5083 can be machined without cutting fluid. Also, both cutting speed and undeformed chip thickness have statistical significance on the cutting and feed force components in dry and wet machining. Finally, the appropriate ranges for the optimal turning conditions were proposed for industrial production.