Contributions Regarding the High-Speed Milling of Parts with Low Rigidity Made from Aluminum Alloys

Abstract

The present work aims to optimize the processing parameters to minimize the geometric deviations of thin-walled parts machined from 6061-T651 aluminum alloy by high-speed milling (HSM). The experimental tests were carried based on a factorial design of experiments, which included as input factors axial cutting depth, cutting speed, and feed per tooth, resulting in shape deviations but also roughness and hardness of machined surfaces. After machining, the residual stresses were determined to establish, if possible, a cause-effect relationship between parts deviations and the magnitude of stresses involved. The experimental tests allowed us to obtain the optimum machining parameters under maximum productivity conditions that ensure the required geometric precision of parts.