The use of lightweight Aluminium Alloy 7075 (AA7075) in aerospace and automotive industries is increasing due to its exceptional properties, such as high strength, good fatigue resistance, and excellent strength-to-weight ratio. However, this alloy is difficult to machine due to high ductility and heat generation during cutting. Cutting fluids are commonly used to deal with these problems, although they raise environmental concerns. The research aims to enhance drilling efficiency for AA7075, considering environmental impacts, through a greener method, a chilled air system. Their impact on tool wear and cutting force was evaluated through spindle speed, feed rate, and nozzle types by adopting the Taguchi method. Chisel edge wear was discovered to be a major contributor to tool wear. Lower feed rate and slower spindle speed using dual nozzle yielded better tool wear and cutting force performance. These findings provide feasible recommendations for industry practitioners seeking to employ eco-friendly chilled air systems to achieve optimal drilling efficiency for this type of material.
