Process design and optimization for the milling operation of aluminum alloy (AA6063 T6)

Abstract

Aluminum alloy is characterized with excellent mechanical properties such as its high strength to weight ratio, which makes it suitable for many industrial applications. In a bid to reduce the energy consumption and the environmental friendliness of the final product, there is need for effective process design and optimization. Hence, this study considers the process design and optimization for the milling operation of aluminum alloy (AA6063 T6). This is to enhance the overall machining process in terms of process cost and economics and enhance the overall sustainability of the manufacturing process. The design considerations include the orientations of the cutting tool, as well as the process parameters for the machining operations and the energy requirements. The numerical experimentation involves the use of the Response Surface Methodology for the correlation of the process parameters for optimization while the physical experiments were investigated using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling machine, aluminum alloy (AA6063 T6) and a cutting tool (SF550 HRC30-HRC40) for the end milling operation. The comparison of the results obtained from the physical and numerical experiments were correlated in order to develop an optimization model for predicting the rate of material removal. The findings of this work will find suitable application as a decision making tool in the manufacturing industries which employs aluminum alloy for product development most especially for the aerospace, rail and automobile industries.