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<p>The 7××× aluminum alloys are primary structural materials in the aerospace industry. They have high specific strength, low weight, and corrosion resistance. However, machining 7××× aluminum alloys frequently produces abnormal chip patterns characterized by sinuous flows. This phenomenon results in the growth of scale thorns, as well as the propagation of microcracks on the machined surface. This study employs cryogenic machining to analyze how variations in cutting velocity, feed, and tool parameter influence surface characteristics through orthogonal cutting experiments. Micromechanical features and machined surface quality were evaluated through the application of high-resolution electron microscopy and three-dimensional surface topography characterization. The Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS) molecular dynamics simulations, combined with experimental data, reveal the dynamic processes of scale thorns formation and metal lamination. The results demonstrated that the optimized machining parameters and cryogenic cooling effectively reduce the formation of scale thorns and improve surface quality by modulating interfacial friction, suppressing dislocation slip, and controlling shear localization behavior. Based on the above findings, the model of scale thorn forming proposed in this study offers theoretical and technical support for the precision machining of 7××× aluminum alloys.</p>

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Cryogenic Treatment Effects on Scale Thorn and Surface Quality in 7××× Aluminum Alloys Precision Machining

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Xueqin Pang,
  • Xiaodong Yu,
  • Rongbin Deng,
  • Peixuan Zhong,
  • Wenjun Deng

摘要

The 7××× aluminum alloys are primary structural materials in the aerospace industry. They have high specific strength, low weight, and corrosion resistance. However, machining 7××× aluminum alloys frequently produces abnormal chip patterns characterized by sinuous flows. This phenomenon results in the growth of scale thorns, as well as the propagation of microcracks on the machined surface. This study employs cryogenic machining to analyze how variations in cutting velocity, feed, and tool parameter influence surface characteristics through orthogonal cutting experiments. Micromechanical features and machined surface quality were evaluated through the application of high-resolution electron microscopy and three-dimensional surface topography characterization. The Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS) molecular dynamics simulations, combined with experimental data, reveal the dynamic processes of scale thorns formation and metal lamination. The results demonstrated that the optimized machining parameters and cryogenic cooling effectively reduce the formation of scale thorns and improve surface quality by modulating interfacial friction, suppressing dislocation slip, and controlling shear localization behavior. Based on the above findings, the model of scale thorn forming proposed in this study offers theoretical and technical support for the precision machining of 7××× aluminum alloys.