Performance evaluation of cold plasma and h-BN nano-lubricant multi-field coupling assisted micro-milling of aluminum alloy 6061-T651

Micro-milling has been employed in various fields due to its efficiency, flexibility, material, and structural versatility in the machining of small and high-quality parts. However, when micro-milling highly plastic aluminum alloys, it is difficult to produce a smooth surface due to the easy sticking of tools. To solve this problem, a multi-energy field coupling method of adding nano-lubricant to the micro-milling area by minimum quantity lubrication (MQL) and modifying the aluminum alloy by cold plasma (CP) was introduced. In this paper, the experiments of CP and h-BN nano-lubricant minimum quantity lubrication (NMQL) multi-field coupling assisted (CPNMQL) micro-milling of aluminum alloy 6061-T65 were carried out to analyze 3D surface roughness (Sa), tool texture, milling forces (Fx and Fy), and surface morphology. The results revealed that the CP could increase the surface microhardness and improve material removal rate; Cottonseed oil with h-BN nanoparticles exhibited superior lubricating properties; The milling forces Fx and Fy were significantly reduced; Sa (0.029 µm) under CPNMQL condition decreased by 60 %, 72.1 %, 27.5 %, and 53.2 % comparing to dry (0.104 µm), NMQL (0.04 µm), and CP (0.062 µm) conditions. In addition, the smallest and most uniform tool mark texture height and depth of 0.038 µm was obtained under CPNMQL condition, a 76.3 % reduction over dry condition.