What question did this study set out to answer?

This study aims to evaluate how different rake and clearance angles of cutting tools influence cutting forces, surface roughness, and chip formation when machining aluminum alloy EN AW-7075-T6.

August 13, 2026Journal of Manufacturing and Materials ProcessingOpen Access

Influence of Cutting Wedge Geometry Design on Cutting Forces, Chip Formation and Surface Roughness During Free Machining of Aluminum Alloy

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Authors

NSNorbert SzabóJohn von Neumann University GKGábor KónyaJohn von Neumann University

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Implication

Experimental investigation reveals how cutting tool geometry affects forces and surface quality during machining of aluminum alloy.

Key Points

This study aims to evaluate how different rake and clearance angles of cutting tools influence cutting forces, surface roughness, and chip formation when machining aluminum alloy EN AW-7075-T6.
A full-factorial experimental design was utilized with rake angles between 0° and 30° and clearance angles from 5° to 15°.
Custom HSS-E Co5 cutting tools were employed and three independent cutting trials for each geometry were conducted.
Two-way analysis of variance was performed to assess significant effects on cutting forces and surface roughness parameters.
Increasing the rake angle significantly reduced the main cutting force (Fc) and passive force (Fp).
Higher clearance angles led to increased force values and higher surface roughness, with maximum Ra and Rz at a 15° clearance angle.
Chip morphology observations indicated larger rake angles produced smoother chips while smaller rake angles resulted in thicker, curled chips.

Cite This Study

Szabó et al. (2026) studied this question.

synapsesocial.com/papers/6a7d76502b0e0cff3f63fa38 https://doi.org/10.3390/jmmp10080292

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August 13, 2026Journal of Manufacturing and Materials ProcessingOpen Access

Influence of Cutting Wedge Geometry Design on Cutting Forces, Chip Formation and Surface Roughness During Free Machining of Aluminum Alloy

View Full Paper

Ask AI

Bookmark

Authors

NSNorbert SzabóJohn von Neumann University GKGábor KónyaJohn von Neumann University

Discussion

Member takes

Implication

Experimental investigation reveals how cutting tool geometry affects forces and surface quality during machining of aluminum alloy.

Key Points

This study aims to evaluate how different rake and clearance angles of cutting tools influence cutting forces, surface roughness, and chip formation when machining aluminum alloy EN AW-7075-T6.
A full-factorial experimental design was utilized with rake angles between 0° and 30° and clearance angles from 5° to 15°.
Custom HSS-E Co5 cutting tools were employed and three independent cutting trials for each geometry were conducted.
Two-way analysis of variance was performed to assess significant effects on cutting forces and surface roughness parameters.
Increasing the rake angle significantly reduced the main cutting force (Fc) and passive force (Fp).
Higher clearance angles led to increased force values and higher surface roughness, with maximum Ra and Rz at a 15° clearance angle.
Chip morphology observations indicated larger rake angles produced smoother chips while smaller rake angles resulted in thicker, curled chips.

Cite This Study

Szabó et al. (2026) studied this question.

synapsesocial.com/papers/6a7d76502b0e0cff3f63fa38 https://doi.org/10.3390/jmmp10080292

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