Effect of Cutting Environment and Swept Angle Selection in Milling Operation

Cutting fluids are frequently aimed to enhance machinability through cooling, lubricating and flushing actions. However, their use in machining creates major concerns in terms of health footprint and environmental effects throughout their lifecycle. Alternative methods, such as dry cutting and minimum quantity lubrication, were used to mitigate these issues. This research also will investigate the effect of swept angle selection, 30% and 60% of tool diameter step over under different cutting conditions during milling of aluminium alloy material. Their impact on tool wear, surface roughness, burr and chip formation were compared. Results pointed that the application of lower swept angle in conjunction with minimum quantity lubricant system has significantly reduced tool wear, decreased burr and chip formation, as well as improved surface quality as compared to dry machining. The work clearly shows how the importance of swept angle selection and cutting condition in refining machining performance could improve the machinability of the material.