Effect of different machining parameters on the surface roughness of aluminium alloys based on Si and Mg content

Abstract

Aluminium-based alloys are considered lengthily for many applications in engineering areas due to their good mechanical properties. Machining these alloys had attracted the attention of many researchers on how to improve the machining, especially when high manufacturing rate is demanded. Usually, machining these materials poses some difficulties such as burr formation, roughness of the surface, continuous chip formation and build-up edge on cutting edge. In this study, AA6061T6, LM6 and AA5083 aluminium-based alloys were considered to research the optimum drilling parameters with the aim to address the earlier started challenges. Drillings were carried out by using a MAHO three-axis CNC drilling machine with an HSS drilling bit at three different spindle speeds and feed rates. From the results, it was established that each aluminium alloy has different surface roughnesses and this surface roughness decreases as spindle speeds increased. A minimum build-up edge was achieved for AA5083 and AA6061T6 alloys. However, a relatively high BUE was noticed in LM6.