Surface Roughness Modeling with Edge Radius and End Milling Parameters on Al 7075 Alloy Using Taguchi and Regression Methods

Abstract

Tool geometry and edge radius are not only crucial for workpiece surface characteristics determination but they also have direct impacts on tool lifetime. They are created in manufacturing and deformations occur in machining processes. With this regard, precise determination of the geometry is of vital importance. This study focused on process parameters like cutting speed, feed rate, depth of cut, tool geometry, and different coatings, to indicate the effects on surface roughness of the machined product on the basis of two and three-dimensional precise measurements. This paper studies the optimization of process parameters and different coating materials with combined different tool radii to obtain the maximum surface quality for the end milling process of Al 7075 alloy by Taguchi and Regression methods. The results revealed optimum process parameters with the proper coating type. The calculated mathematical model predicts average surface roughness value against edge radius wear and processing parameters.