Evaluation of the Relationship of Surface Roughness with Machining Parameters in Milling of AA 7075 Material with Experimental and Deform 3D Simulation

Abstract

AA 7075 T6 material offers important strength values and is easy to machining. In this respect, it is preferred on a wide scale in the industry. This study aimed to investigate the surface quality that occurs in the end milling of AA 7075 T6 material. For this, 3 different cutting speeds (40, 80, 120 m/min), three different feed rates (0.04, 0.08, 0.12 mm/rev), 2 different cutting depths (1 and 2 mm) were selected. The selected cutting parameters are combined with 2 and 4-flute end mills. As a result of the experiments, the average surface roughness (Ra) value was measured. The relations of Ra values with the cut parameters were determined. It was determined that Ra increased with increasing feed rate and decreased with increasing cutting speed. No significant effect of depth of cut was detected. Increasing the number of mouths increased Ra. The milling simulation was performed with the 3D cutting module in the Deform 3D software. 2 and 4 flute end mills are modeled, and the workpiece is defined to the software and the cutting parameters. Temperature, damage, stress, and cutting force outputs were estimated through simulations run at different cutting parameters. The predicted outputs and the experimental Ra outputs were interpreted and interpreted. Experimental outputs were supported by successfully applying milling simulation in Deform 3D software.

Keywords

• AA 7075 T6
• milling
• surface roughness
• flute number
• Deform 3D
• simulation

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