Track: Manufacturing

Abstract

This research reports the optimization of milling process for Al7075 aerospace alloy under dry cutting conditions employing Response Surface Methodology (RSM). The influence of various control parameters such as spindle speed (RPM), feed rate (ƒ_z) and axial depth of cut (a_p) are examined to improve the surface roughness (R_a) and the material removal rate (MRR). A set of 20 test trials using a central composite design (CCD) is utilized for the design of experimentation (DOE). The second-order polynomial regression equations are developed to predict the response attributes. In addition, the RSM-based parametric and variance exploration is made to quantify the effects of milling variables on the output characteristics. Lastly, the RSM-based Desirability Function is adopted for multi-attribute optimization. By applying this approach, the following have been obtained: a minimum R_aof 0.26 µm and maximum MRR of 2196E+04 mm³/min at the spindle speed 2577.32 rpm, the ƒ_z531.650 mm/min, and the a_p4.6330 mm.