Experimental data on surface roughness and force feedback analysis in friction stir processed AA7075 – T651 aluminium metal composites

Friction Stir Processing (FSP) is a surface modification technique used to enhance the mechanical properties and improve the surface integrity of the processed material. In the present data collection, aluminium alloy 7075-T651 was studied under different reinforcement conditions. Microchannel of dimension 3.5 mm depth and 2.0 mm width were machined on the aluminium plates to accommodate the particles. The process was conducted at different rotational speed of 1200 rpm, 1500 rpm and 1800 rpm with constant processing speed of 20 mm/min, plunge depth of 0.3 mm and tilt angles of 3°. Double passes were achieved for each parameter with 100% inter-pass overlap. A cylindrical tapped, AISI H13 steel tool with shoulder diameter 18 mm, pin length of 5.0 mm, pin diameter 5 mm at the top and 6 mm at the end with 10° taper was used during friction stir process. Surface integrity analysis was carried out with the aid of mitutoyo surftest SJ-210 surface roughness tester (SRT). The analysis was carried out at three different points on a parameter for a particular workpiece and the average reading for each parameter is calculated in order to ensure precision of the measurements and the coverage surface area. The following surface roughness parameters were measured and recorded, arithmetical mean roughness value (Ra), maximum height (Ry), mean roughness depth (Rz) and root mean square roughness (Rq). Force feedback from the machine data for selected reinforcement particles with respected to processing times and x-positions are also presented.