Abstract
The best surface quality that can be achieved in manufactured products has become the main goal of industrial enterprises in recent years. Due to the subsequent increase in energy consumption costs from rising energy efficiency rates, manufacturers are contributing to this issue by applying advanced design functions for their machines. In line with the same objective, this study investigated the machinability of 6061 aluminum alloy, which has a high throughput rate and low machinability featuring built up edge. The aim of the research was to optimize the cutting parameters for minimum surface roughness (Ra) and energy consumption (EC) using a CNC milling machine. At the same time, measurements of power indices (A) of both the spindle and the X‐axis motors were carried out with the goal of improved chip removal as compared to literature studies. The experiment was designed according to the Taguchi L16 (21 × 43) orthogonal index. Four different cutting speeds (60, 120, 180, and 240 m/min), feed rates (0.10, 0.15, 0.20, and 0.25 mm/rev), and cutting depths (0.5, 0.10, 0.15, and 0.20 mm) and two different cooling methods (coolant fluid and dry cutting) were selected as cutting parameters.
Highlights
Today, energy saving has become a significant consideration in the manufacture of both consumer products and industrial equipment
In the slot milling of Al T6061 alloy, a number of milling experiments were performed and experimental and statistical analyses on energy consumption and surface roughness were carried out. e experiments were designed according to the Taguchi L16 orthogonal array and reached optimal surface roughness (Ra and Rz) and energy consumption (Pcutting S, Pcutting X, specific energy consumption (SEC) S, and SEC X) values in a shorter time with 16 experiments instead of 128, resulting in savings of time and cost. is study determined the energy consumption of both servo motors used in the processing of the 6061 alloy, which is widely used in industry but has low workability due to BUE
The effects of these energy consumption values on the surface roughness values were determined. e cutting parameters effective on energy consumption and surface roughness were determined via analysis of variance (ANOVA)
Summary
Energy saving has become a significant consideration in the manufacture of both consumer products and industrial equipment. Cutting condition effects on power consumption in the drilling and end milling of S45C carbon steel were determined by Mori et al using a vertical machining center [7]. Advances in Materials Science and Engineering consumption and surface roughness in the end milling of austenitic stainless steel under cryogenic, fluid coolant and dry cutting conditions [13]. Nas and Ozturk applied face milling to a spheroidal graphite cast iron workpiece, measured the increase in the consumed power index (PI) with an ammeter device, and optimized the machining process with two different cutting tools [14]. The aim was to optimize the cutting parameters to yield minimum surface roughness with minimum energy consumption during the manufacturing process by using the Taguchi method. The slot milling operation was investigated for the first time under both dry and wet (coolant fluid) cutting conditions
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