Title: Optimisation of cutting parameters during the face milling of AA5083-H111 with coated and uncoated inserts using Taguchi method

Authors: Gürcan Samtaş

Addresses: Department of Mechatronics Engineering, Engineering Faculty, Düzce University, Konuralp Yerleşkesi, 81620 Beci Yörükler, Düzce, Turkey

Abstract: Aluminium 5083-H111 alloy is used in many different sectors such as shipbuilding, rail cars and vehicle bodies. The use of this material in different sectors, its behaviours in the various machining operations have become important. In this study, face milling process was applied to AA5083-H111 material by using coated and uncoated cutting inserts. Experiments were performed on the basis of Taguchi's L18 orthogonal array (OA) at different levels of the cutting depth (0.08, 0.25 mm), the cutting inserts (uncoated carbide, PVD/TiAlN coated carbide, PVD/TiB2 coated carbide), the cutting speed (450, 550, 650 m/min) and the feed rate (0.08, 0.12, 0.25 mm/tooth) relating to a good surface quality. The obtained values at the end of the experiments were evaluated through the signal to noise (S/N) ratios, analysis of variance (ANOVA), 3D graphs and regression method. Through the confirmation experiments, the machining accuracy of 0.52 µm could be significantly improved to 0.24 µm with an enhanced performance of 53.84%.

Keywords: surface roughness; Taguchi methods; optimisation; aluminium alloys; cutting parameters; face milling; coated inserts; uncoated inserts; surface quality; orthogonal arrays; cutting depth; cutting speed; feed rate.

DOI: 10.1504/IJMMM.2015.071993

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.3/4, pp.211 - 232

Received: 19 May 2014
Accepted: 22 Feb 2015
Published online: 27 Sep 2015 *

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