An Investigation of Optimum Cutting Conditions in Face Milling Semi-Solid Cast 6061 Aluminum Alloy Using Carbide Tool

Abstract

The purpose of this research was to investigate the effect of the main factors of the surface roughness in semi-solid 6061 aluminum face milling. This study was conducted by using computer numerical controlled milling machine. The controlled factors were the speed, the feed rate and the depth of cut which the depth of cut was not over 1 mm. For this experiment, we used factorial designs and the result showed that the factors effected of surface roughness was the feed rate and the speed while the depth of cut did not effect with the surface roughness. Furthermore, the surface roughness was likely to reduce when the speed was 4,200 rpm and the feed rates was 1,300 mm/min. The result of the research led to the linear equation measurement value which was Ra = 0.186 - 0.000034 Speed + 0.000047 Feed rate. The equation formula should be used with the speed in the range of 3,200-4,200 rpm, feed rate in the range of 1,300-1,800 mm/min and the depth of cut not over 1 mm. The equation was used to confirm the research results, it was found that the mean absolute percentage error of the surface roughness obtained from the predictive comparing to the value of the experiment was 4.12%, which was less than the specified error and it was acceptable.