Parameter Optimization during Finish End Milling of Al Alloy 5083 using Robust Design

Abstract

The influence of cutter geometry and cutting parameters during end milling on the surface texture of aluminium (Al) alloy 5083 was experimentally investigated. Eighteen pockets were manufactured having different combination of parameters values according to Taguchi L18 standard orthogonal array. Surface texture parameters (Ra, Ry, and R z) were measured on three different passes on side surface of pockets and analyzed using statistical techniques. The results reveal that the cutting speed, the peripheral 2nd relief angle, and the core diameter have significant effect in surface texture parameters. In order to establish a relationship between the performance measures and the process parameters, a set of additive models was produced. Finally, an evaluation (verification) experiment was performed. The acquired experimental values were found to be inside the confidence intervals provided by the additive models. These results confirm the accuracy of the proposed modeling approach.