Analysis and Optimization of Process Parameters Affecting Form Errors and Surface Roughness in Milling of Aging-Treated AA 6063-T6 Free Form Surfaces

Authors : Yavuz Çodur, Barış Özlü, Halil Demir

Pages : 155-171

Doi:10.52795/mateca.1535125

View : 56 | Download : 59

Publication Date : 2024-12-30

Article Type : Research Paper

Abstract :This study aimed to examine the microstructure and hardness changes in AA 6063 T6 specimens that underwent an ageing procedure. The second portion involves the machining of free forms surfaces on specimens with varying microstructures and hardness. Four different tool paths, four different cutting speed (Vc), and four different feed rate (f) were employed in the machining of the surfaces. Statistical analysis were conducted to ascertain the optimal cutting parameters and their impact on the output parameters. The experimental design was designed based on the Taguchi L16 index. The form errors and surface roughness values acquired from the tests were analysed statistically using the Signal/Noise (S/N) ratio and analysis of variance (ANOVA) methods. The study found that the sample immersed in 2WQ solution had a minimum hardness value of 71.7 Hv1, whereas the sample aged for 18 hours had a maximum hardness value of 117.7 Hv1. Based on the investigation, it was determined that A4B1C4 yielded the most favourable cutting parameter in terms of form error and surface roughness. This refers to the utilisation of the TP4 tool path, a f of 0.04 mm per tooth, and a Vc of 105 m/min. Based on the data collected, the ANOVA analysis of the 18AQ sample revealed that the cutting parameters with the highest efficacy in minimising form error and surface roughness were a f of 51.18% and 59.07%, respectively. These values represent the optimum values for cutting parameters.
Keywords : AA 6063-T6, Yaşlandırma, Form hatası, Yüzey pürüzlülüğü, Optimizasyon