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Machinability Assessment of Aluminium Alloy EN AW-7075 T651 Under Varying Machining Conditions Cover

Machinability Assessment of Aluminium Alloy EN AW-7075 T651 Under Varying Machining Conditions

Acta Mechanica et Automatica
Volume 19 (2025): Issue 2 (June 2025)
By: Jarosław KORPYSA,  Magdalena ZAWADA-MICHAŁOWSKA,  Paweł PIEŚKO,  Witold HABRAT and  Joanna LISOWICZ  
Open Access
|Jun 2025

Figures & Tables

Fig. 1.

Experimental setup: a) schematic diagram; b) experimental procedure
Experimental setup: a) schematic diagram; b) experimental procedure

Fig. 2.

Cutting speed vs surface roughness parameters: a) Ra; b) Rz; c) RSm (fz = 0.1 mm/tooth)
Cutting speed vs surface roughness parameters: a) Ra; b) Rz; c) RSm (fz = 0.1 mm/tooth)

Fig. 3

Feed per tooth vs surface roughness parameters: a) Ra; b) Rz; c) RSm (vc = 300 m/min)
Feed per tooth vs surface roughness parameters: a) Ra; b) Rz; c) RSm (vc = 300 m/min)

Fig. 4.

Variable feed per tooth vs surface roughness parameters: a) Ra; b) Rz; c) RSm (vc = 900 m/min)
Variable feed per tooth vs surface roughness parameters: a) Ra; b) Rz; c) RSm (vc = 900 m/min)

Fig. 5.

Variations in the cutting force component Fx during a milling process conducted with variable vc
Variations in the cutting force component Fx during a milling process conducted with variable vc

Fig. 6.

Variations in the cutting force component Fx during a milling process conducted with variable fz (vc = 300 m/min)
Variations in the cutting force component Fx during a milling process conducted with variable fz (vc = 300 m/min)

>Fig. 7.

Variations in the cutting force component Fx during a milling process conducted with variable fz (vc = 900 m/min)
Variations in the cutting force component Fx during a milling process conducted with variable fz (vc = 900 m/min)

Fig. 8.

Variable cutting speed vs cutting force for: a) PCD; b) carbide tool (fz = 0.1 mm/tooth)
Variable cutting speed vs cutting force for: a) PCD; b) carbide tool (fz = 0.1 mm/tooth)

Fig. 9.

Feed per tooth vs cutting force for: a) PCD; b) carbide tool (vc = 300 m/min)
Feed per tooth vs cutting force for: a) PCD; b) carbide tool (vc = 300 m/min)

Fig. 10.

Feed per tooth vs cutting force for: a) PCD; b) carbide tool (vc = 900 m/min)
Feed per tooth vs cutting force for: a) PCD; b) carbide tool (vc = 900 m/min)

Parameters of milling process

vc (m/min)fz (mm/tooth)n (rpm)vf (mm/min)
1000.1002 654796
3007 9622 389
50013 2703 981
70018 5775 573
90023 8857 166
3000.0507 9621 194
0.0751 791
0.1002 389
0.1252 986
0.1503 583
9000.05023 8853 583
0.0755 374
0.1007 166
0.1258 957
0.15010 748

Regression equations for the cutting force components

ComponentPCDCarbide
vc
Fxy = 2.1734 × 10-6x3 - 0.0031486x2 + 1.3387x – 181.5044y = 6.8696 × 10-7x3 - 0.00046211x2 - 0.022684x + 194.5068
R2 = 0.92574R2 = 0.99967
Fyy = 2.6357 × 10-6x3 - 0.0040011x2 + 1.6079x – 134.8438y = 9.7847 × 10-7x3 - 0.0012124x2 + 0.31351x + 103.4101
R2 = 0.80254R2 = 0.97897
Fzy = 2.3882 × 10-7x3 - 0.00033649x2 + 0.19507x – 160.758y = -4.3391 × 10-8x3 + 0.00019882x2 - 0.053533x + 44.2173
R2 = 0.92635R2 = 0.9991
fz (vc = 300 m/min)
Fxy = -96682.6667x3 + 25468.1943x2 + 496.6658x + 165.8101y = 97571.7333x3 - 26474.3086x2 + 3036.7114x + 25.412
R2 = 0.99988R2 = 0.99437
Fyy = 109699.2x3 - 42818.3886x2 + 6999.1857x - 33.956y = -58838.9333x3 + 19257.8057x2 - 2257.4428x + 210.1391
R2 = 0.99976R2 = 0.99969
Fzy = 15057.0667x3 - 12366.2514x2 + 2759.5016x + 25.1968y = -275146.5067x3 + 96013.5394x2 - 10386.9419x + 395.9015
R2 = 0.96265R2 = 0.99571
fz (vc = 900 m/min)
Fxy = 170491.7333x3 - 52457.1543x2 + 5869.7915x + 178.4637y = 413898.1333x3 - 141383.1543x2 + 15794.7885x - 288.4818
R2 = 0.98706R2 = 0.9745
Fyy = 232014.1333x3 - 79230.3303x2 + 8143.1002x + 12.1011y = 29947.2x3 - 15807.84x2 + 2755.607x - 17.3301
R2 = 0.87723R2 = 0.84802
Fzy = 57291.3067x3 - 17403.6217x2 + 2089.9487x + 147.4216y = 947917.8133x3 - 281117.8789x2 + 26232.8967x - 631.465
R2 = 0.98346R2 = 0.99651

Regression equations for surface roughness parameters

ParameterPCDCarbide
vc
Ray = -2.2396 × 10-9x3 + 3.7195 × 10-6x2 - 0.0022461x + 1.6193y = 1.1458 × 10-9x3 - 2.0223 × 10-6x2 + 0.00014211x + 2.1396
R2 = 0.99992R2 = 0.99358
Rzy = -5.2083 × 10-10x3 + 5.1339 × 10-7x2 - 0.00072693x + 5.555y = 3.125 × 10-9x3 - 3.9732× 10-6x2 - 0.00049554x + 6.8933
R2 = 0.93879R2 = 0.99697
RSmy = -7.5521 × 10-10x3 + 1.0158 × 10-6x2 - 0.00042798x + 0.22112y = -1.0417 × 10-10x3 + 9.1964 × 10-8x2 - 0.00010467x + 0.24011
R2 = 0.96237R2 = 0.99545
fz (vc = 300 m/min)
Ray = 8.8889x3 - 43.2381x2 + 16.6754x + 0.001y = 1493.3333x3 - 416x2 + 44.2667x + 0.39
R2 = 0.99686R2 = 1
Rzy = -4800x3 + 1228.5714x2 - 73.7143x + 5.23y = 533.3333x3 - 148.5714x2 + 23.381x + 5.24
R2 = 0.99256R2 = 0.99824
RSmy = -57.7778x3 + 9.1619x2 + 1.4737x + 0.0045667y = 5.3333x3 - 2.0571x2 + 0.8481x + 0.15
R2 = 0.97841R2 = 0.99985
fz (vc = 900 m/min)
Ray = -1395.5556x3 + 396.381x2 - 23.104x + 0.88433y = -320x3 + 137.1429x2 - 8.8286x + 1.42
R2 = 0.93968R2 = 0.97975
Rzy = -1244.4444x3 + 161.9048x2 + 38.0635x + 0.73333y = 1.1446 × 10-11x3 + 11.4286x2 + 11.7143x + 4.4
R2 = 0.99764R2 = 0.98848
RSmy = -268.4444x3 + 88.0571x2 - 7.6403x + 0.28237y = 21.3333x3 - 5.8286x2 + 1.1324x + 0.077
R2 = 0.9568R2 = 0.99786
DOI: https://doi.org/10.2478/ama-2025-0037 | Journal eISSN: 2300-5319 | Journal ISSN: 1898-4088
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Language: English
Page range: 300 - 308
Submitted on: Feb 7, 2025
Accepted on: May 2, 2025
Published on: Jun 30, 2025
Published by: Bialystok University of Technology
In partnership with: Paradigm Publishing Services
Publication frequency: 4 issues per year
Keywords:
milling,
aluminium alloy,
surface roughness,
cutting force,
cutting tools
Related subjects:
Engineering,
Electrical engineering,
Electronics,
Mechanical engineering,
Mechanics,
Bioengineering and biomedical engineering,
Biomechanics,
Civil engineering,
Environmental engineering

© 2025 Jarosław KORPYSA, Magdalena ZAWADA-MICHAŁOWSKA, Paweł PIEŚKO, Witold HABRAT, Joanna LISOWICZ, published by Bialystok University of Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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