Abstract
Magnesium alloy is one of the lightest materials with a high strength to weight ratio and excellent machinability, which makes it attractive and suitable for various industrial applications such as automotive and aerospace components. For these particular industrial components, the end products require a mirror-like finish. This article details a statistical analysis about the effect of milling parameters on the surface roughness of Magnesium alloy AZ91D in the dry milling process. The historical data approach in the response surface methodology (RSM) was utilized to determine the cause and effect relationship between the input variables and output response. The effect of milling parameter studied was cutting speed (900 – 1400 m/min), feed rate (0.03 - 0.09 mm/tooth), and radial depth of cut (0.2 - 0.3 mm). The results confirmed that the interaction between feed rate and cutting speed is the primary factor controlling the surface evolution. The responses of various factors were plotted using a two-dimensional interaction graph and the cubic empirical model was developed at 95% confidence level. The optimum condition for achieving the minimum surface roughness was a cutting speed of 977 m/min, a feed rate of 0.02 mm/tooth, and an axial depth of cut of 0.29 mm. With this optimum condition, a surface arithmetic roughness of 0.054 μm is expected. This study confirmed that by milling AZ91D at high speed cutting, it is possible to eliminate the polishing process to achieve a super mirror-like finishing.
Highlights
Current interest is focused on the growing demand for more fuelefficient vehicles that reduces energy consumption and air pollution
Magnesium alloys are known for its excellent physical and mechanical properties, such as low density, very high strength to weight ratio, high stiffness, and mechanical cast ability. They are preferred over aluminium or steel alloys in the automotive industry due to its promising high strength to weight ratio
The Ra values for surface roughness measured were in the range of 0.057- 0.393 μm for all of the 72 experimental runs, i.e. less than 0.5 μm, which is equivalent to manual polishing [13]
Summary
Current interest is focused on the growing demand for more fuelefficient vehicles that reduces energy consumption and air pollution. Magnesium alloys are known for its excellent physical and mechanical properties, such as low density, very high strength to weight ratio, high stiffness, and mechanical cast ability They are preferred over aluminium or steel alloys in the automotive industry due to its promising high strength to weight ratio. Leading car manufacturers are investigating the replacement of steel with lighter materials, such as magnesium, to achieve lightweight construction without sacrificing rigidity This can lead to greenhouse gas reductions and limit the amount of exhaust emissions, both of which satisfy legislative and consumers’ requirements for safer and cleaner vehicles [3]. Despite the growing interest in magnesium alloys, very little data exist on the wear behaviour of the tool after the machining process and the influence of cutting fluid during the machining process Most lightweight materials, such as magnesium, are widely used in the automotive and truck manufacturing industries [4]. We will show that the interaction between feed rate and cutting speed is the primary factor that controls the surface evolution
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