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<p>This study aims to investigate the impact of cutting parameters on the tool wear mechanism in the micro-cutting of 7075 aluminum alloy. By employing experimental and simulation methods, the influence of cutting speed, cutting depth, and tool rake angle on tool temperature, as well as the maximum stress and equivalent stress on the tool’s rake and flank faces, is examined. Additionally, SEM analysis of the tool at different cutting speeds is conducted. The results indicate that tool temperature increases with both cutting speed and cutting depth. Increasing the cutting speed from 200 to 800&#xa0;mm/min leads to a substantial rise in temperature. Similarly, increasing the cutting depth from 10 to 40&#xa0;μm significantly elevates the tool temperature. However, tool temperature initially decreases and then increases with the increase in the tool rake angle, reaching its lowest at 8° and measuring 105.23&#xa0;°C. At lower cutting speeds, adhesive wear is the primary form of tool wear. At a cutting speed of 600&#xa0;mm/min, craters start forming on the tool tip and rake face, gradually leading to spalling wear. The maximum compressive stress on the rake face rises with cutting parameters, while on the flank face it decreases with increasing cutting speed, first decreases then increases with cutting depth, and increases with rake angle. The highest compressive stresses on the rake and flank faces occur at 400&#xa0;mm/min, 12° rake angle, and 40&#xa0;μm cutting depth, reaching approximately 2978.86&#xa0;MPa and 3437.04&#xa0;MPa, respectively. To minimize maximum equivalent stress, the optimal parameters are 400&#xa0;mm/min cutting speed, 20&#xa0;μm cutting depth, and 12° rake angle.</p>

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Study on the Influence of Tool Geometric Parameters on Tool Wear Mechanism of 7075 Aluminum Alloy Cutting

  • 期刊论文

  • 发表日期：

    2025年12月15日

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  • Ping Zhang,
  • Shuai Ge

摘要

This study aims to investigate the impact of cutting parameters on the tool wear mechanism in the micro-cutting of 7075 aluminum alloy. By employing experimental and simulation methods, the influence of cutting speed, cutting depth, and tool rake angle on tool temperature, as well as the maximum stress and equivalent stress on the tool’s rake and flank faces, is examined. Additionally, SEM analysis of the tool at different cutting speeds is conducted. The results indicate that tool temperature increases with both cutting speed and cutting depth. Increasing the cutting speed from 200 to 800 mm/min leads to a substantial rise in temperature. Similarly, increasing the cutting depth from 10 to 40 μm significantly elevates the tool temperature. However, tool temperature initially decreases and then increases with the increase in the tool rake angle, reaching its lowest at 8° and measuring 105.23 °C. At lower cutting speeds, adhesive wear is the primary form of tool wear. At a cutting speed of 600 mm/min, craters start forming on the tool tip and rake face, gradually leading to spalling wear. The maximum compressive stress on the rake face rises with cutting parameters, while on the flank face it decreases with increasing cutting speed, first decreases then increases with cutting depth, and increases with rake angle. The highest compressive stresses on the rake and flank faces occur at 400 mm/min, 12° rake angle, and 40 μm cutting depth, reaching approximately 2978.86 MPa and 3437.04 MPa, respectively. To minimize maximum equivalent stress, the optimal parameters are 400 mm/min cutting speed, 20 μm cutting depth, and 12° rake angle.