Experimental Investigation of the Effect of Independent Parameters in the Face Milling of Aluminum 6082 Alloy

Abstract

Face milling is the vital process, which takes away the material from the top surface. This work comprehends the selection of desirable milling parameters like spindle speed (SS), feed rate (FR) and depth of cut (DoC) over machining time, material removal rate and surface roughness. The complex technical reasons like shearing action, dribbling, furrowing, churning and piling were identified concerning the parameter considered. The SS is associated with shearing action or incisaling with plowing, FR causes furrowing and DoC concerns the piling action over the material, affecting the responses. The mathematical model was developed through response surface methodology (RSM). Later, an assessment was made between the predicted and experimental data so as to perceive the consistency of the developed model. The surface plot of RSM has greater concurrence with the white light interferometer images, which is evident for the technical reason. The maximized productivity and better part quality are decided based on the appropriate machining parameter selection. Therefore, optimization is carried out through the genetic algorithm to obtain the desired input parameters. The optimal values of SS, FR and DoC for minimizing the responses are found to be 4978.51 rpm, 598.242 mm/min. and 1.499 mm, respectively.