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

Abstract

Aluminum alloys are being extensively used almost in all engineering fields owing to their wide range of mechanical properties. Machining of the aluminum alloys is one of the research area that focusses primarily on improved machining with high production rate. In machining of aluminum alloys, some common problems are faced, i.e. surface roughness, build-up edge on cutting edge, burr formation and continuous chip formation. This research was carried on three different aluminum alloys namely AA6061T6, AA5083 and LM6 to investigate the optimum drilling parameters for improved chip morphology, surface roughness, build-up edge and burr formation. The drills were performed by using a MAHO three axis CNC drilling machine with a HSS drill bit at three different spindle speeds and feed rates. It was found that the surface roughness was different for each aluminum alloy and it was found to be decreasing with increased spindle speeds. The BUE was found to be minimum for AA6061T6 and AA5083 but was quite high for LM6.