Examination of surface roughness values of 6061-T6 aluminum material after machining and after anodizing process

Abstract

The use of aluminum material is very common, especially in parts that require precision mechanical processing, such as in the aerospace or defense industry. Since weight reduction in related vehicles or technologies in the fields of aviation and defense industry is one of the biggest goals, the use of aluminum as a metal material has become one of the first targets. The high weight/strength ratio of aluminum compared to steel is one of the main reasons why it is preferred. In addition to these advantages of aluminum materials, we have two expectations for 6061 aluminum parts in most of the projects we work on. The first is to minimize the frictional intensity of the aluminum parts working in contact with each other. The second is to provide the surface roughness of the gasket pressing surface on the surfaces where gaskets are used due to the need for sealing. For both requirements, our goal in this study will be to achieve the surface roughness value as maximum Ra 0.2 after machining and maximum Ra 0.3 after anodizing. The study was carried out with six different cutting tools. These tools, in order; end mill (with one insert) cutter, end mill (with two inserts) cutter, solid end mill, single insert diamond tool, monocrystalline diamond tool and superfinishing tool. Particular attention was paid to the cleanliness of the chemical baths used in the anodizing specific to this study. As a result, it has been observed that much more precise results can be achieved than the currently accepted surface roughness value when suitable machining parameters and optimum anodizing coating parameters are used. By using different cutting parameters with the same tool, by increasing the speed and feed values and decreasing the depth of cut, there is a slight improvement in the surface roughness values. The results of the experiments are presented in table and graphic and are suitable only for observed cutting conditions, used tools and material.