Assessments of Process Parameters on Cutting Force and Surface Roughness during Drilling of AA7075/TiB2 In Situ Composite

Reinforced aluminum composites are the basic class of materials for aviation and transport industries. The machinability of these composites is still an issue due to the presence of hard fillers. The current research is aimed to investigate the drilling topographies of AA7075/TiB2 composites. The samples were prepared with 0, 3, 6, 9 and 12 wt.% of fillers and experiments were conducted by varying the cutting speed, feed, depth of cut and tool nose radius. The machining forces and surface topographies, the structure of the cutting tool and chip patterns were examined. The maximum cutting force was recorded upon increase in cutting speed because of thermal softening, loss of strength discontinuity and reduction of the built-up-edge. The increased plastic deformation with higher cutting speed resulted in the excess metal chip. In addition, the increase in cutting speed improved the surface roughness due to decrease in material movement. The cutting force was decreased upon high loading of TiB2 due to the deterioration of chips caused by fillers. Further introduction of TiB2 particles above 12 wt.% weakened the composite; however, due to the impact of the microcutting action of the fillers, the surface roughness was improved.