Comparative Analysis of Face Milling in Dry and Wet Condition of Al 8011 For Minimum Surface Roughness in Face Milling

Abstract

Abstract: The quality of machined components is evaluated in respect of how closely they adhere to set product finish, and reflective properties. Dimensional accuracy, tool wear and quality of surface finish are three factors that manufacturers must be able to control at the machining operations to ensure better performance and service life of engineering component. Aluminum alloys are extensively used as a main engineering material in various industries such as automotive industries, the mould and the die components manufacture and the industry in which weight is the most important factor. The purpose of this research is to investigate the effect of the main factors of the surface roughness and flatness in aluminum 8011 face milling with dry and wet condition. This experimental investigation to be conducted by using VMC controlled milling machine with 30mm face milling cutter with carbide multiple inserts. The same parameters were executed during the operation only difference minimum quantity lubricant for one set of operation and another set of operation without lubricant. The experimental results were evaluated using Taguchi technique minimum surface finish obtained at medium speed and maximum feed and depth of cut 0.222 µm in the dry condition during the face milling operation. The minimum flatness was obtained 0.012 mm at wet condition. minimum surface finish obtained through dry condition. Optimal control factor and ANNOVA calculations were found for face milling operation of AA8011.