Machinability of stir-cast Al7075-based hybrid nanocomposites under dry and compressed-air cooling conditions

¹ Vishwakarma Institute of Information Technology, Affiliated to Savitribai Phule Pune University, Pune, India
² Vishwakarma Institute of Technology, Affiliated to Savitribai Phule Pune University, Pune, India
³ D Y Patil International University, Akurdi, Pune, India

^* Corresponding author: suhas.221p0007@viit.ac.in

Published online: 7 January 2026

Abstract

In this study, the machinability of the stir-cast Al7075-based hybrid nanocomposites is evaluated during turning under dry and compressed air-cooling conditions. Based on experimental findings, mathematical models were created that can forecast the machining performances, namely cutting force, surface roughness, and flank wear. Using the ANOVA technique, the impact of different Al7075-based hybrid nanocomposites and cutting parameters, specifically, cutting speed, feed, and depth of cut, on various responses was examined. According to experimental findings, higher cutting forces and lower surface roughness were obtained while turning harder Al7075-based nanocomposites. Under compressed air machining conditions, the surface roughness, cutting force, and flank wear were observed to decrease by 4.74%, 8.84% and 43.59% respectively. The flank wear analysed for different cutting conditions showed a substantial reduction in the flank wear while turning under compressed air-cooling conditions. Moreover, lower flank wear could also be attributed to the displacement of the abrasive particles from the cutting edge. The chip morphology is studied for the various cutting conditions as well as different machining environments. SEM analysis was carried out to compare the surface texture of the chips produced under dry and compressed air conditions.