Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy

Zhen-Jing Duan; Shuai-Shuai Wang; Shu-Yan Shi; Ji-Yu Liu; Yu-Heng Li; Zi-Heng Wang; Chang-He Li; Yu-Yang Zhou; Jin-Long Song; Xin Liu

doi:10.1007/s40436-024-00530-z

Advances in Manufacturing ›› : 1 -19. DOI: 10.1007/s40436-024-00530-z

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Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy

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¹ State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology, 116024, Dalian, Liaoning, People’s Republic of China

² School of Materials Science and Engineering, Dalian University of Technology, 116024, Dalian, Liaoning, People’s Republic of China

³ School of Mechanical and Automotive Engineering, Qingdao University of Technology, 266520, Qingdao, Shandong, People’s Republic of China

^k xinliu@dlut.edu.cn

Zhen-Jing Duan is a doctoral candidate at the State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian, China. His research interests include precision and non-traditional machining technology, multi-energy field composite machining technology, machinability, and surface integrity.

Shuai-Shuai Wang is a doctoral candidate at the State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian, China. His research interests include precision and non-traditional machining technology, multi-energy field composite machining technology, machinability, and surface integrity.

Shu-Yan Shi is an engineer at the School of Materials Science and Engineering at the Dalian University of Technology, Dalian, China. Her research interest is material microstructure analysis.

Ji-Yu Liu acquired his Ph.D. degree under the guidance of Prof. Zhuji Jin at Dalian University of Technology in 2021. His research interests involve non-traditional machining, surface engineering, and extreme wettability.

Yu-Heng Li is a doctoral candidate at the State Key Laboratory of High-Performance Precision Manufacturing at Dalian University of Technology, Dalian, China. Her research interests include plasma modifications.

Zi-Heng Wang is a doctoral candidate at the State Key Laboratory of High-Performance Precision Manufacturing at Dalian University of Technology, Dalian, China. His research interests include precision and nontraditional machining technology, machinability, and surface integrity.

Chang-He Li is a foreign academician at the Russian Academy of Engineering, a professor, and a doctoral supervisor at the School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, China. His research interests include grinding and precision machining; quasi-dry green manufacturing; intelligent manufacturing equipment; production lines; and intelligent agricultural machinery.

Yu-Yang Zhou is a doctoral candidate at the State Key Laboratory of High-Performance Precision Manufacturing at Dalian University of Technology, Dalian, China. Her research interests include bionic super-wetting interface functional materials, marine antifouling materials, and anticorrosion materials.

Jin-Long Song is a professor and doctoral supervisor at the State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology, Dalian, China. His research interests include the fabrication and application of functional surfaces with microstructures, additive/subtractive manufacturing using microelectrochemistry, and green cleaning technology and equipment.

Xin Liu is a professor and doctoral supervisor at the State Key Laboratory of High-Performance Precision Manufacturing at Dalian University of Technology, Dalian, China. His research interests include precision and nontraditional machining technology, multienergy field composite machining technology, high-performance valve design and manufacturing, cold plasma medical applications, preparation and application of superimpregnated functional surfaces, electrochemical machining technology, and ultrasonic-assisted machining technology.

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Abstract

Micromilling has been extensively employed in different fields such as aerospace, energy, automobiles, and healthcare because of its efficiency, flexibility, and versatility in materials and structures. Recently, nanofluid minimum quantity lubrication (NMQL) has been proposed as a green and economical cooling and lubrication method to assist the micromilling process; however, its effect is limited because high-speed rotating tools disturb the surrounding air and impede the entrance of the nanofluid. Cold plasma can effectively enhance the wettability of lubricating droplets on the workpiece surface and promote the plastic fracture of materials. Therefore, the multifield coupling of cold plasma and NMQL may provide new insights to overcome this bottleneck. In this study, experiments on cold plasma + NMQL multifield coupling-assisted micromilling of a 7075-T6 aluminum alloy were conducted to analyze the three-dimensional (3D) surface roughness (S _a), surface micromorphology, burrs of the workpiece, and milling force at different micromilling depths. The results indicated that, under cold plasma + NMQL, the workpiece surface micromorphology was smooth with fewer burrs. In comparison with dry, N₂, cold plasma, and NMQL, the S _a values at different cutting depths (5, 10, 15, 20 and 30 μm) were relatively smaller under cold plasma + NMQL with 0.035, 0.036, 0.041, 0.043 and 0.046 μm, which were respectively reduced by 38.9%, 45.7%, 45.9%, 47% and 48.9% when compared to the dry. The effect of cold plasma + NMQL multifield coupling-assisted micromilling on enhancing the workpiece surface quality was analyzed using mechanical analysis of tensile experiments, surface wettability, and X-ray photoelectron spectroscopy (XPS).

Keywords

Micro-milling / Nanofluid minimum quantity lubrication (NMQL) / Cold plasma / Environmentally friendly / Three-dimensional (3D) surface roughness

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Zhen-Jing Duan,Shuai-Shuai Wang,Shu-Yan Shi,Ji-Yu Liu,Yu-Heng Li,Zi-Heng Wang,Chang-He Li,Yu-Yang Zhou,Jin-Long Song,Xin Liu. Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy. Advances in Manufacturing 1-19 DOI:10.1007/s40436-024-00530-z