Optimizing the High-Performance Milling of Thin Aluminum Alloy Plates Using the Taguchi Method

Cheng-Hsien Kuo,Zi-Yi Lin

doi:10.3390/met11101526

Abstract

Most aerospace parts are thin walled and made of aluminum or titanium alloy that is machined to the required shape and dimensions. Deformation is a common issue. Although the reduced cutting forces used in high-speed milling generate low residual stress, the problem of deformation cannot be completely resolved. In this work, we emphasized that choosing the correct cutting parameters and machining techniques could increase the cutting performance and surface quality and reduce the deformation of thin plates. In this study, a part made of a thin 6061 aluminum alloy plate was machined by high-speed milling (HSM), and a Taguchi L16 orthogonal array was used to optimize the following parameters: linear velocity, feed per tooth, cutting depth, cutting width, and toolpath. The impact of cutting parameters on the degree of deformation, surface roughness, as well as the cutting force on the thin plate were all investigated. The results showed that the experimental parameters for the optimal degree of deformation were A1 (linear velocity 450 mm/min), B1 (feed per tooth 0.06 mm/tooth), C1 (cutting depth 0.3 mm), D4 (cutting width 70%), and E4 (rough zigzag). Feed per tooth was the most significant control factor, with a contribution as high as 63.5%. It should also be mentioned that, according to the factor response of deformation, there was a lower value of feed per tooth and less deformation. Furthermore, the feed per tooth and the cutting depth decreased and the surface roughness increased. The cutting force rose or fell with an increase or decrease of cutting depth.

Highlights

There are several ways to reduce the degree of deformation [4], and one involves the reduction of residual stress
The results show that applying a correctly selected machining technique minimizes the deformation of thin-walled elements [17]
The cutting parameters taken into consideration were linear velocity, feed per tooth, cutting depth, cutting width, and toolpath

Summary

Introduction

Aerospace parts are no longer as thick and heavy as they were in the early days These parts can be much lighter as a result of geometric improvements made through finite element analysis simulation and topology optimization. The 6000 series of aluminum alloys is the most extensively used primary material in aerospace It is used for fuselage framework as well as outer frame structures. The degree of deformation can be lowered by effective reduction of residual stress. This can often be achieved by smaller cutting depth, lower cutting force, changes in process strategy, flexible design, and prompt removal of heat [5,6,7,8]. A flexible design can include a frame of material around the thin part, which is removed after the processing has been completed [9,10]

Methods

Discussion

Conclusion