Experiment and simulation on the high-speed milling mechanism of aluminum alloy 7050-T7451

This study aims to investigate how milling parameters and tool geometric parameters affect the milling mechanism of aluminum alloy 7050-T7451. A two-dimensional high-speed milling model of aluminum alloy 7050-T7451 is established based on Advantedge; the effects of milling parameters (milling speed, cutting depth) and tool geometric parameters (tool rake angle, tool blunt radius) on milling force and milling temperature are identified through single factor experiment. The results show that as milling speed increases, Fx first reduces and then increases, whereas Fy first increases and then reduces; milling temperature first increases and then gradually reduces after a given speed is reached, but the overall change is modest. Milling depth is positively correlated to milling force and milling temperature. As tool rake angle increases, both milling force and milling temperature reduce. Tool blunt radius is positively correlated to Fx and Fy and makes no difference to milling temperature. •The effects of different tool geometry parameters on machinability were studied.•Finite element models of 7050-T7451 aluminum alloy with different milling parameters were established.•The forming mechanism of milling has been proved.