Machinability analysis in high-speed milling of AlSi7Mg alloys under EMQL conditions: An approach toward sustainable manufacturing

Abstract

Electrostatic minimum quantity lubrication (EMQL) is a newly-developed cooling method dedicated to crucial manufacturing processes; however, its applicability under the high-speed machining (HSM) of aluminum alloys remains poorly understood. In this paper, parametric tests under the EMQL condition and their comparisons with the dry, flood cooling, and conventional MQL conditions were conducted during the HSM of AlSi7Mg alloys. The specific energy consumption, machined surface morphologies, and wear signatures at the tool edge were experimentally investigated. Based on the results obtained, the machinability of AlSi7Mg under EMQL is characterized, and the feasibility of EMQL is addressed. The EMQL generally shows better lubricating and cooling effects in the HSM of AlSi7Mg alloys, in which the best-machined surface quality and the least tool wear and adhesion are achieved. The cutting depth is noted as the most influential factor affecting the machined surface roughness under the EMQL conditions. The compatibility of the EMQL with the HSM of AlSi7Mg alloys is confirmed in this study, and technical guidance for selecting cutting parameters is offered for the manufacturing community.