Abstract
In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061
Highlights
Milling is a common machining process, and one of the most used in computer numerical control (CNC) machines
The ANOVA results that were used to evaluate the effect of cutting parameters on the tool wear and surface roughness with 95 % confidence level and 5 % significance level
The analysis results in these tables show that: During the machining processing of aluminum alloy Al6061 with the carbide cutting insert, after different machining strokes (10 strokes, 30 strokes, and 50 strokes), the parameter that has most influence on the tool wear was the cutting speed (from 52.18 %, (2021), «EUREKA: Physics and Engineering» Number 3 to 84.94 %)
Summary
Milling is a common machining process, and one of the most used in computer numerical control (CNC) machines. Many studies were performed to evaluate the effect of technological parameters and cutting conditions on the tool wear and machining surface roughness to improve the quality (2021), «EUREKA: Physics and Engineering» Number 3 and reduce the cost and time of machining processes. These studies were performed with the normal cutting conditions and with different machining methods such as grinding [1], drilling [2], turning [3,4,5,6], milling [7,8,9,10], and so on. The results from these studies showed that depending on the machining time or the number of machining strokes, the tool wear and surface roughness changed [16, 17, 20]
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