Milling operation parameter optimization of AA 2024-T351 aluminum alloy material

Abstract

The expected quality indicator in the manufacturing industry is the surface roughness (R a). The effects of milling operation parameters on the axial forces and surface roughness of AA 2024-T351 alloy plate were studied. Experiments were carried out on an AA 2024 material using a Hartford four-axis computer numerical control vertical processing center machine and a carbide insert. Axial forces were measured by using a three-component cutting force dynamometer. R a values ranged from 0.2583 to 0.8833 μm and the cutting force from 76 to 305 N. Experimental results showed that cutting forces rose with an increase in cutting speed but R a values decreased with a rise in cutting speed. Also, the depth of cut was the commanding factor followed by spindle speed and feed per tooth. This indicated that cutting depth was the most important factor among the design parameters, followed by cutting speed and feed per tooth. Besides, the response surface methodology was used to investigate the milling parameters on R a and axial forces. Variance analysis was conducted to find the contribution of each component to the results of roughness and forces. Scanning electron microscopy analysis was also performed to see the abrasions on the cutting tool surface.