An Investigation and Analysis of Cutting Force and Tool Wear in Dry Pocket Milling of Aluminum Alloy Al7075

This experimental study investigated the effects of milling conditions on the cutting forces and tool wear. The dry pocket milling processes of the aluminum alloy Al7075 were performed to investigate the influence of the cutting conditions on the cutting forces and tool wear. With three controllable factors-three levels (depth of cut, feed rate, and cutting speed), the experimental design with 11 experiments that was selected to carried out. The effect of cutting conditions on the cutting forces and tool wear were analyzed by The ANOVA analysis. In pocket milling process, the most important factor affecting on the cutting forces and tool wear as well was feed rate. The second factor that influenced on the cutting forces and tool wear was depth of cut. The factor that had smallest influence on the cutting forces and tool wear was cutting speed. The most suitable regression of cutting forces and tool wear was a linear regression with the almost confidence level is more than 95 %, and all regression models were successfully verified by experimental results. In additions, the relationship between cutting forces and tool wear was also analyzed. The investigated models of this study can be applied in industrial machining to optimize the anergy comsumption and tool life in dry pocket milling process of the aluminum alloy Al7075