Surface roughness of hypereutectic Al-Si A390 in high speed milling

Abstract

The most important measures of surface quality during the machining process is the average surface roughness (Ra), and it is mostly caused by machining parameters, such as cutting speed, feed rate, depth of cut, etc. This paper presents the effect of cutting parameters on surface roughness for a cutting speed of 900 to 1700 m/min, feed rate of 0.02 to 0.06 mm/tooth and depth of cut of 0.2 to 0.4mm. The analysis of variance (ANOVA) is applied to determine the effects of the machining parameters on the surface roughness, later the mathematical model for the surface roughness was developed. From the ANOVA, it was found that cutting speed and feed rate were the significant factors that affecting the surface roughness. The optimum condition for machining parameter was suggested by the Design Expert software when machining at cutting speed of 1490 mm/min, feed rate of 0.03 mm/tooth and depth of cut at 0.29 mm. At this cutting parameter the surface roughness value is predicted at 0.24µm which is similar with the surface roughness than can be obtained using manual grinding.

Keywords

• High speed milling
• Dry cutting
• Hypereutectic Al-Si alloys
• Surface roughness
• Cutting parameters