Optimization Of Machining Parameters In High Speed Milling Of Aluminum 6061

Lim , Chong Wei (2009) Optimization Of Machining Parameters In High Speed Milling Of Aluminum 6061. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

This report presents the optimization of machining parameters in high speed milling of aluminum 6061. Aluminum is widely used in industry such as automation, aerospace and others industry. High speed milling is selected either than using conventional milling because it produce more precision final products and also mass production. The goal of research is to determine the possible effect of high speed milling by conducting the surface roughness test on workpieces that produced by different parameters setting. Consequently, the optimum parameters for surface roughness can be done. In this study, the RSM method was used to design and analysis the experiment. There are 20 trials conducted by using 3-axis high speed milling machine. The surface roughness produced was checked by using surface roughness tester. The surface roughness value was analysis in the Design Expert Software using RSM method. From the Design Expert software, quadratic model is suggested based on analysis the Box-Cox, Normal Plot and Predicted versus actual Graph. The significant parameters suggested were cutting speed and feed rate while depth of cut is not a significant factor. For the optimization section, the best predicted setting was cutting speed of 5000rpm, feed rate of 256mm/min and depth of cut of 0.25mm. The average deviation percentage value was about 30%. This might cause by cutting tool wear. More blocks were recommended so that noise effect will reduced and improved the surface quality. The objective was archived if the actual value is near to the predicted value Lastly, the particular study of new invention could improve help the industry to save a lot of unnecessary cost besides improve the products quality so that could increase the challengers in the global market.

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