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

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
• Aging
• Form error
• Surface Roughness
• Optimization

Yaşlandırma İşlemi Uygulanmış AA 6063-T6 Serbest Formlu Yüzeylerin Frezelenmesinde Form Hatalarının ve Yüzey Pürüzlülüğünü Etkileyen Proses Parametrelerinin Analizi ve Optimizasyonu

Abstract

Bu çalışmanın amacı, yaşlandırma prosedürüne tabi tutulan AA 6063-T6 numunelerindeki mikroyapı ve sertlik değişimlerini incelemektir. İkinci kısım, farklı mikroyapı ve sertliğe sahip numuneler üzerinde serbest formlu yüzeylerin işlenmesini içerir. Yüzeylerin işlenmesinde dört farklı takım yolu, dört farklı kesme hızı (Vc) ve dört farklı ilerleme miktarı (f) kullanılmıştır. Optimum kesme parametrelerini ve bunların çıktı parametreleri üzerindeki etkilerini belirlemek için istatistiksel analiz yapılmıştır. Deneysel tasarım Taguchi L16 dizinine göre tasarlanmıştır. Testlerden elde edilen form hataları ve yüzey pürüzlülük değerleri, Sinyal/Gürültü (S/N) oranı ve varyans analizi (ANOVA) yöntemleri kullanılarak istatistiksel olarak analiz edilmiştir. Çalışmada, 2WQ çözeltisine daldırılan numunenin minimum sertlik değerinin 71.7 Hv1, 18 saat yaşlandırılan numunenin ise maksimum sertlik değerinin 117.7 Hv1 olduğunu bulmuştur. Yapılan inceleme sonucunda A4B1C4'ün form hatası ve yüzey pürüzlülüğü açısından en uygun kesme parametresini verdiği belirlenmiştir. Bu, TP4 takım yolunun, diş başına 0.04 mm'lik bir ilerleme hızının ve 105 m/dak'lık bir kesme hızının kullanılması anlamına gelmektedir. Toplanan veriler ışığında 18AQ numunesinin ANOVA analizi, form hatasını ve yüzey pürüzlülüğünü en aza indirmede en yüksek etkinliğe sahip kesme parametrelerinin sırasıyla %51.18'lik bir ilerleme hızı ve %59.07'lik bir ilerleme hızı olduğunu ortaya koymuştur. Bu değerler kesme parametreleri için optimum değerleri temsil etmektedir.

Keywords

• AA 6063-T6
• Yaşlandırma
• Form hatası
• Yüzey pürüzlülüğü
• Optimizasyon

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