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Materials 2014, 7(3), 1603-1624; doi:10.3390/ma7031603

Surface Finish and Residual Stresses Induced by Orthogonal Dry Machining of AA7075-T651

*  and
Aluminum Research Centre (REGAL) and École de technologie supérieure (ÉTS), Département mécanique, 1100 rue Notre-Dame Ouest, Montréal, QC H3C 1K3, Canada
* Author to whom correspondence should be addressed.
Received: 19 December 2013 / Revised: 20 February 2014 / Accepted: 24 February 2014 / Published: 28 February 2014
(This article belongs to the Special Issue Light Alloys and Their Applications)


The surface finish was extensively studied in usual machining processes (turning, milling, and drilling). For these processes, the surface finish is strongly influenced by the cutting feed and the tool nose radius. However, a basic understanding of tool/surface finish interaction and residual stress generation has been lacking. This paper aims to investigate the surface finish and residual stresses under the orthogonal cutting since it can provide this information by avoiding the effect of the tool nose radius. The orthogonal machining of AA7075-T651 alloy through a series of cutting experiments was performed under dry conditions. Surface finish was studied using height and amplitude distribution roughness parameters. SEM and EDS were used to analyze surface damage and built-up edge (BUE) formation. An analysis of the surface topography showed that the surface roughness was sensitive to changes in cutting parameters. It was found that the formation of BUE and the interaction between the tool edge and the iron-rich intermetallic particles play a determinant role in controlling the surface finish during dry orthogonal machining of the AA7075-T651 alloy. Hoop stress was predominantly compressive on the surface and tended to be tensile with increased cutting speed. The reverse occurred for the surface axial stress. The smaller the cutting feed, the greater is the effect of cutting speed on both axial and hoop stresses. By controlling the cutting speed and feed, it is possible to generate a benchmark residual stress state and good surface finish using dry machining.
Keywords: machining; aluminum; surface finish; residual stress; carbide tool machining; aluminum; surface finish; residual stress; carbide tool
This is an open access article distributed under the Creative Commons Attribution License (CC BY) which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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Jomaa, W.; Songmene, V.; Bocher, P. Surface Finish and Residual Stresses Induced by Orthogonal Dry Machining of AA7075-T651. Materials 2014, 7, 1603-1624.

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