Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy

Abstract

The best surface quality that can be achieved in manufactured products has become the main goal of industrial enterprises in recent years. Due to the subsequent increase in energy consumption costs from rising energy efficiency rates, manufacturers are contributing to this issue by applying advanced design functions for their machines. In line with the same objective, this study investigated the machinability of 6061 aluminum alloy, which has a high throughput rate and low machinability featuring built up edge. The aim of the research was to optimize the cutting parameters for minimum surface roughness (Ra) and energy consumption (EC) using a CNC milling machine. At the same time, measurements of power indices (A) of both the spindle and the X-axis motors were carried out with the goal of improved chip removal as compared to literature studies. The experiment was designed according to the Taguchi L16 (21 × 43) orthogonal index. Four different cutting speeds (60, 120, 180, and 240 m/min), feed rates (0.10, 0.15, 0.20, and 0.25 mm/rev), and cutting depths (0.5, 0.10, 0.15, and 0.20 mm) and two different cooling methods (coolant fluid and dry cutting) were selected as cutting parameters.