Effect of cutting parameters on machinability of 7075-T651 aluminum alloy in different processing methods.

The aim of this study was to explore the influence of cutting parameters on the cutting performance of 7075-T651 aluminum alloy under different processing methods. Using finite element software, normal cutting, x-direction ultrasonic vibration cutting, y-direction ultrasonic vibration cutting, and elliptical ultrasonic vibration cutting processes were simulated with various values of the cutting parameters. The results showed that when the cutting speed was between 160 and 280 m/min, with the increase of the cutting speed, the main cutting force value under the four processing methods increases gradually. At 280–320 m/min, the main cutting force value of normal cutting showed a downward trend. The cutting force increased with the increase of feed and cutting depth. At the same time, the increase of cutting speed and feed increased the cutting temperature and the temperature of the blade-to-chip contact area. However, cutting depth had little influence on the temperature during the cutting process. When the cutting parameters changed, the cutting temperatures of the four machining modes were in the following order: elliptical vibration cutting > y-direction vibration cutting > x-direction vibration cutting > normal cutting. When the cutting speed and feed increased, the magnitude and depth of residual stress increased to a certain extent. As the cutting depth increased, the heat generated by the cutting increased, but most of the heat was carried away by the chips, resulting in lower influence of the thermal stress and phase changes on the residual stress. [ABSTRACT FROM AUTHOR]