Optimization of high speed machining cutting parameters for end milling of AlSi7Cu4 using Taguchi based technique of order preference similarity to the ideal solution

Abstract

Aluminum alloys with silicon as the main alloying element constitute a class of materials and account for the most important part of all materials used in casting. These alloys are widely used in the automotive and aerospace industries due to their excellent casting and mechanical properties, as well as good corrosion and wear resistance. The addition of trace alloying elements (such as Cu and Mg) can improve mechanical properties and make the alloy sensitive to heat treatment. This study used the Technique of Order Preference Similarity to the Ideal Solution (TOPSIS) technology to examine the optimization of the operating parameters of the AlSi7cu4 end mill with multiple response criteria based on the Taguchi orthogonal array. Nine experiments were carried out based on the Taguchi L9 orthogonal array. Spindle speed, feed rate, depth of cut and insert corner radius have been optimized for various performance characteristics, such as surface roughness, material removal rate, residual stress and chip thickness. The TOPSIS score from the analysis is used to solve the multifunctional milling process. In addition, analysis of variance (ANOVA) can also be used to determine the most important factors. Finally, a confirmatory test is performed to compare the experimental results with the developed model. Experimental results show that this method can effectively improve the processing efficiency of end mills.