Large Strain Extrusion Machining of 7075 Aluminum Alloy with Micro-Textured Tools and Analysis of Chip Morphology and Microstructure

Large Strain Extrusion Machining (LSEM) is an intensive plastic deformation process evolved from conventional machining, enabling effective control over chip morphology and grain refinement. This process often generates high cutting temperatures and frictional instability during machining, which degrades material properties and accelerates tool wear. This study proposes a technique combining microtextured tools with LSEM to optimize cutting performance. By designing different microtextured tools (parallel-to-cutting-edge microtextured tools (P-T) and perpendicular-to-cutting-edge microtextured tools (V-T)), cutting experiments were conducted on 7075 aluminum alloy to systematically investigate the effects of microtextured LSEM on cutting performance and chip formation. Results indicate that microtextured tools effectively reduce cutting temperatures. Compared to non-textured tools (N-T), microtextured tools can lower maximum cutting temperatures by up to 13.20% (36.56 °C). Microtextured LSEM suppresses serration formation, leading to more stable chip formation. The serration degree of chips produced by microtextured tools was reduced by up to 25.66% compared to N-T tools. XRD analysis indicates that microtextured tools significantly increase chip dislocation density, reaching nearly 2.77 times that of N-T tools, enhancing material microhardness and refining grain size. This study confirms that combining microtextured tools with LSEM synergistically optimizes chip morphology and improves the microstructural properties of Al7075, providing technical support for machining high-strength aluminum alloys.