Experimental and Numerical Investigation of Effective Parameters in Milling Process of 7075 Aluminum Alloy Using Taguchi Method

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Mohammad Reza Bahmani ¹ , Reza Abedinzadeh ^{2 *}

1 - Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Khomeinishahr, Iran
2 - Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Isfahan, Iran

Received: 2023-01-25 Accepted : 2023-03-31 Published : 2025-06-02

Keywords: 7075 aluminum alloy, Milling, Finite element method, Cutting force, Taguchi.,

Abstract :

In the present research, the effective parameters in the milling process of 7075 aluminum alloy were investigated in both experimental and numerical methods. In this regard, cutting depth, feed rate, spindle rotational speed and number of tool teeth were considered as input parameters of the experiment. Then, the effect of these factors on cutting force, surface roughness and machining temperature was investigated using Taguchi design of experiment. Next, the obtained output results were evaluated using the signal-to-noise (S/N) method. Also, the numerical simulation of the milling process was carried out using the finite element method in Deform-3D software. Finally, a comparative study of numerical and experimental results was performed on the cutting force. The results showed that feed rate and depth of cut had the greatest effect on cutting force and surface roughness. Rotational speed also has the greatest effect on machining temperature. The optimal levels of the parameters to reduce the cutting force were the cutting depth of 1 mm, feed rate of 8 mm/min, rotational speed of 200 rpm and number of tool teeth of 2. Moreover, the cutting depth of 1 mm, feed rate of 8 mm/min, rotational speed of 400 rpm and number of tool teeth of 3 were considered as the optimal levels to reduce the surface roughness. The results obtained from the numerical analysis of the milling process regarding the cutting force were in good agreement with the experimental results of the process.

References:

[1] Santos, MC., Machado, AR., Sales, WF., Barrozo, MA., Ezugwu, EO. (2016). Machining of aluminum alloys: a review. The International Journal of Advanced Manufacturing Technology, 86(9-12), 3067-3080.
[2] Sequeiera, A., Deepak, D., Sachidananda, H.K. (2023). Experimental study on machining of AA7075 using Taguchi method. SN Applied Sciences, 5(11), 1-8.
[3] Munoz-Escalona, P., Maropoulos, PG. (2015). A geometrical model for surface roughness prediction when face milling Al 7075-T7351 with square insert tools. Journal of Manufacturing Systems, 36, 216-223.
[4] Pour, M., Torabizadeh, MA. (2016). Improved prediction of stability lobes in milling process using time series analysis. Journal of Intelligent Manufacturing, 27(3), 665-677.
[5] Pinar, AM., Filiz, S., Ünlü, BS. (2016). A comparison of cooling methods in the pocket milling of AA5083-H36 alloy via Taguchi method. The International Journal of Advanced Manufacturing Technology, 83(9), 1431-1440.
[6] Karabulut, Ş., Çinici, H., Karakoç, H. (2016). Experimental Investigation and Optimization of Cutting Force and Tool Wear in Milling Al7075 and Open-Cell SiC Foam Composite. Arabian Journal for Science and Engineering, 41(5), 1797-1812.
[7] Najiha, MS., Rahman, PDMM., Kadirgama, K. (2015) Machining performance of aluminum alloy 6061-T6 on surface finish using minimum quantity lubrication. International Journal of Automotive and Mechanical Engineering, 11, 2699.
[8] Tsai, M., Chang, S., Hung, J., Wang, C. (2016). Investigation of milling cutting forces and cutting coefficient for aluminum 6060-T6. Computers & Electrical Engineering, 51, 320-330.
[9] Nurhaniza, M., Ariffin, M., Mustapha, F., Baharudin, B. (2016). Analyzing the effect of machining parameters setting to the surface roughness during end milling of CFRP-Aluminium composite laminates. International Journal of Manufacturing Engineering, 2016, 1-9.
[10] Kulkarni, HB., Nadakatti, MM., Kulkarni, SC., Kulkarni, RM. (2020). Investigations on effect of nanofluid based minimum quantity lubrication technique for surface milling of Al7075-T6 aerospace alloy. Materials Today: Proceedings, 27, 251-256.
[11] Sahoo, SP., Datta, S. (2020). Dry Machining Performance of AA7075-T6 Alloy Using Uncoated Carbide and MT-CVD TiCN-Al2O3-Coated Carbide Inserts. Arabian Journal for Science and Engineering,45(11), 9777-9791.
[12] Jomaa, W., Mechri, O., Lévesque, J., Songmene, V., Bocher, P., Gakwaya, A. (2017). Finite element simulation and analysis of serrated chip formation during high–speed machining of AA7075–T651 alloy. Journal of Manufacturing Processes, 26, 446-458.
[13] Shoba, C., Ramanaiah, N., Rao, DN. (2015). Effect of reinforcement on the cutting forces while machining metal matrix composites: An experimental approach. Engineering Science and Technology, an International Journal, 18(4), 658-663.
[14] Dabade, U., Jadhav, M. (2016). Experimental study of surface integrity of Al/SiC particulate metal–matrix composites in hot machining. Procedia CIRP, 41, 914-919.
[15] Mehdi, K., Zghal, A. (2012). Modelling cutting force including thrust and tangential damping in peripheral milling process. International Journal of Machining and Machinability of Materials, 12(3), 236-251.
[16] Dwivedi, S., Kumar, S., Kumar, A. (2012). Effect of turning parameters on surface roughness of A356/5% SiC composite produced by electromagnetic stir casting. Journal of Mechanical Science and Technology, 26(12), 3973-3979.
[17] Sahoo, A., Pradhan, S., Rout, A. (2013) Development and machinability assessment in turning Al/SiCp-metal matrix composite with multilayer coated carbide insert using Taguchi and statistical techniques. Archives of civil and mechanical engineering, 13, 27-35.
[18] Davoodi, B., Hosseinzadeh, H. (2012). A new method for heat measurement during high speed machining. Measurement, 45(8), 2135-2140.