Investigation on machinability characteristics during turning Al6063 alloy using uncoated carbide insert

Abstract

The present study cites the machinability characteristics during turning Al6063 alloy utilizing uncoated carbide inserts in dry environment through Taguchi L9 orthogonal array with parametric optimization and modeling of responses such as arithmetic mean surface roughness (Ra) and tool flank wear (VBc). Tool flank wear increases with rise of cutting speed, feed and depth of cut whereas surface roughness increases with cutting feed with negligible effect of cutting speed and depth of cut. With parametric combination of cutting speed (80 m/min), feed (0.04 mm/rev) and depth of cut (0.2 mm), low tool wear, c- type discontinuous chips and the thin groves produced on the finished surface with evidence of built-up-edge formation. By analyzing the grey relational grade, optimal parametric combinations have been determined. Feed is found to be the major significant input variable on responses from ANOVA. Confirmatory test evidently depicts the enhancement of grey relational grade. Regression models are statistically significant due to high determination coefficients and P-value is < 0.05.The residuals recline rationally proximal to a straight line from normal probability plot signifying that the errors are disseminate normally and models for all responses are significant.