Application of experimental data based on Taguchi approach to optimize machining parameters of Al6061T6 to reduce cutting forces and moments

Abstract

The requirements for the quality and accuracy of manufactured products are constantly increasing. Reliability, durability, and accuracy of machine operation largely depend on the quality of surface treatment. Study on the cutting process, in particular milling, makes it possible to find out the operating conditions of the cutting tool, determine the acting cutting forces, torques, vibrations and temperatures on it. Along with studying the influence of various parameters on the milling process, it is necessary to pay special attention to establishing the nature and degree of influence of the cutting condition (cutting speed, depth of cut and feed rate). In this paper milling operation of Al6061-T6 was performed in a dry condition. The effects of cutting parameters on cutting forces and moments in different directions and around various axes were studied. By applying Taguchi technique and performing experiments, it was shown that cutting force was significantly affected by feed rate followed by rotational speed and cutting depth. Cutting moment is mainly influenced by feed rate, cutting depth, and rotational speed. Moreover, feed rate is the most effective factor on minimizing cutting forces and moments. Finally, the optimum cutting parameters was revealed to get a minimum cutting forces and moments.

Keywords

• aluminum alloy
• milling
• machining parameter
• taguchi method
• cutting force
• vibration