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.

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