Title: Cutting force, torque, and hole quality in vibration-assisted helical milling of AA7075

Authors: Mariam Nabil Ali; Amr B. Eltawil; Hassan El-Hofy

Addresses: Department of Industrial and Manufacturing Engineering, School of Innovative Design Engineering, Egypt-Japan University of Science and Technology, P.O. Box 179, New Borg El-Arab City, 21934, Alexandria, Egypt; Department of Mechanical Design and Production, Faculty of Engineering, Zagazig University, 44519, Zagazig, Egypt ' Department of Industrial and Manufacturing Engineering, School of Innovative Design Engineering, Egypt-Japan University of Science and Technology, P.O. Box 179, New Borg El-Arab City, 21934, Alexandria, Egypt; Department of Production Engineering, Faculty of Engineering, Alexandria University, 21544, Alexandria, Egypt ' Department of Industrial and Manufacturing Engineering, School of Innovative Design Engineering, Egypt-Japan University of Science and Technology, P.O. Box 179, New Borg El-Arab City, 21934, Alexandria, Egypt; Department of Production Engineering, Faculty of Engineering, Alexandria University, 21544, Alexandria, Egypt

Abstract: Recently, an ultrasonic vibration-assisted technique has been utilised to improve the hole-making process of aerospace materials. However, there was a lack in discussing the effect of applying ultrasonic vibration and different cutting conditions on the hole quality during vibration-assisted helical milling (VAHM). Therefore, this work experimentally and statistically investigated the impact of VAHM variables on the machinability of AA7075 alloy. The process parameters included axial helical pitch, tangential feed rate, ultrasonic vibration assistance, and different fluid supply techniques of dry, minimum quantity lubrication, and flood. The machining evaluation was performed by computing cutting force, torque, hole quality concerning hole diameter, out-of-roundness, hole conicity, burr height, and surface roughness. Analysis of variance (ANOVA) was conducted to determine the significant factors and their percentage contribution. The ultrasonic vibration was found to have an insignificant effect on hole diameter, and surface roughness; however, it reduces out-of-roundness, burr height, torque, and hole conicity.

Keywords: ultrasonic vibration; helical milling; AA7075 alloy; cutting force; hole accuracy; burr height; surface roughness.

DOI: 10.1504/IJMMM.2021.117663

International Journal of Machining and Machinability of Materials, 2021 Vol.23 No.4, pp.369 - 391

Received: 17 Dec 2020
Accepted: 10 Mar 2021

Published online: 16 Sep 2021 *

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