Effect of Ranque-Hilsch Vortex Tube Cooling to Enhance the Surface-Topography and Tool-Wear in Sustainable Turning of Al-5.6Zn-2.5Mg-1.6Cu-0.23Cr-T6 Aerospace Alloy

The aerospace metal cutting industry’s search for environmentally friendly practices that do not compromise machining performance is well known. One of the major objectives is the reduction in use of cutting fluids, which play a major role in containing the harsh effects of severe heat generated during machining. Machining performance and product quality can be improved by controlling heat during machining. The purpose of this study was to determine the effectiveness of various environmentally friendly metalworking fluid (MF) strategies for the sustainable turning of aerospace aluminum alloy (Al-5.6Zn-2.5Mg-1.6Cu-0.23Cr-T6) for automotive, marine, and aerospace industrial applications. The SEM images were analyzed for worn tool surfaces and machined surfaces. Under dry conditions, heat does not dissipate well, and will enter the workpiece due to the absence of coolant. This causes extreme damage beneath a turned workpiece. Thus, at 10 µm, a drop in microhardness of approximately 20% can be observed. A similar observation was made in a Ranque-Hilsch vortex tube (RHVT) and in compressed air; however, the drop in hardness was relatively low compared to dry conditions. This evaluation of microhardness indicated a heat-based attention in the turned workpiece, and thus, the heat-based effect was found to be lowest in RHVT and compressed air compared to dry conditions. Results showed that RHVT reduces temperature up to 10%, surface roughness 13%, and tool wear 20% compared to dry turning. Overall, RHVT was identified as more effective environmentally friendly cooling strategy than dry and compressed air for the turning of aluminum alloy 7075-T6.