Experimental study on the effect of CNT-enriched nanofluid lubrication on the performance of textured cutting tool in the turning of aluminum 7075 alloy

Abstract

This paper investigates the impact of surface texturing and the use of CNT-enriched nanofluid lubrication on the cutting performance of cemented carbide cutting tools during the turning process of aluminum 7075 alloy. Aluminum 7075 is widely utilized in various industries due to its exceptional properties, including high corrosion resistance, a favorable strength-to-weight ratio, and good formability. However, this alloy tends to excessively adhere to the cutting tool at the tool-chip interface, which negatively affects the machining process. Previous research has proposed different solutions, but the current study focuses on implementing the two most effective approaches to minimize adhesion phenomena. The first approach involves modifying the contact area by creating a pattern on the tool's rake face, while the second approach utilizes CNT-enriched nanofluid lubrication to reduce friction in the tool-chip interface. Various types of surface textures were fabricated on the rake face, and experimental tests were conducted to identify the most effective texture. The findings showed that using textured tools with micro-grooves perpendicular to the chip flow direction, with CNT-enriched nanofluid lubrication, resulted in significant reductions in main cutting force, built-up edge, and surface finish. The decreases were up to 32%, 37%, and 19%, respectively, compared to dry turning conditions.