Slot milling of AA7075 reinforced with nano silicon carbide particles: An experimental and finite element approach

In the current trend, industries prefer to optimize machining processes using finite element-based machining simulation techniques. Aluminum alloy 7075 (AA7075) strengthened with nano silicon carbide particles (nSiCp) is utilized by industries as they exhibit good physical and mechanical properties. Slot milling is the essential machining operation to convert the component to the designed shape and size. However, excellent knowledge is required in selecting the appropriate machining parameters such as cutting velocity, feed, and cutting tool material to ensure the quality of the components milled. In this research work, slot milling operation is carried out in the sample plates of AA7075 fortified with nSiCp content to 1.5% of the weight. A 3D finite element model (3D FEM) is developed using ABAQUS software for simulating slot milling operations to understand the influence of machining parameters on cutting forces, chip formation, and chip morphology. The cutting force signals predicted by 3D FEM correlates 85 to 90% with experimental data. The maximum shear stress of 175 MPa and Von Mises stress of 459 MPa were observed at the tool-workpiece interface. This validated 3D FEM facilitates to visualize and investigate the milling process and assists in selecting appropriate machining parameter settings. The effects of cutting velocity and feed on cutting forces, chip characteristics, stress, and chip formation are reported.