Title: Evaluation of machining parameters on specific cutting energy consumption in the turning of Al 7075 alloy in dry conditions using Taguchi and desirability approach

Authors: A. Kannan; N.M. Sivaram

Addresses: Department of Mechanical Engineering, Sustainable Manufacturing Laboratory, National Institute of Technology Puducherry, Karaikal – 609 609, India ' Department of Mechanical Engineering, Sustainable Manufacturing Laboratory, National Institute of Technology Puducherry, Karaikal – 609 609, India

Abstract: In the present study, Al 7075 alloy was turned using an uncoated tungsten carbide cutting tool. The number of experiments conducted was 27, as per the Taguchi L₂₇ OA design plan. Turning operation was performed without the presence of cutting fluid, which makes it to be the most sustainable form of machining. Evaluating the specific cutting energy (SCE) required to remove the unit volume of material is the novelty of the present study. Responses considered were SCE and surface roughness (Ra). Optimisation of the input parameters was executed for individual cases using the Taguchi approach, and simultaneous optimisation was carried out using the desirability approach (DA). The 100 m/min cutting speed, 0.1 mm/rev feed rate, and 1 mm depth of cut combination produces the optimal value for SCE, and the 200 m/min cutting speed, 0.05 mm/rev feed rate, and 1 mm depth of cut combination makes the optimal value for Ra, considering the individual response optimisation. This study optimised the turning of Al 7075 alloy using a tungsten carbide tool in a dry, sustainable process. Through 27 Taguchi designed experiments, optimal parameters for minimising specific cutting energy (SCE) and surface roughness (Ra) were identified. The best combined setting (200 m/min speed, 0.075 mm/rev feed, 1 mm depth) reduced SCE by 88.31% and Ra by 14.48%, achieving a low SCE of 0.166 J/mm³, promoting sustainable machining.

Keywords: machining; Al 7075 alloy; specific cutting energy; SCE; Taguchi method; composite desirability; CD; sustainability.

DOI: 10.1504/IJMMM.2026.150475

International Journal of Machining and Machinability of Materials, 2026 Vol.28 No.1, pp.90 - 106

Received: 08 Jan 2025
Accepted: 01 Apr 2025
Published online: 15 Dec 2025 *

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