World Journal of Engineering Research and Technology

*U. D. Gulhane, Akshay Patil, Sagar Masram, Vaibhav Kamble, Girish Mathakar

ABSTRACT

The Al 6061 alloy has a wide variety of applications in automobile industries as well as aerospace industries due to its light weight to strength ratio, high corrosion resistance, heat treatable and easily weldable property. Quality and productivity are two important aspects for manufacturing industries for that purpose milling is the best option for machining of Al 6061. Milling is a process having wide variety of applications in the industry. While machining on the milling machine Surface Roughness (Ra) and Material Removal Rate are two output parameters comes into the picture. Surface roughness is influencing on allowance and external appearance of the final product. In this investigation, we are going to analyse process parameters are temperature, speed, feed and depth of cut. The research papers which are studied by us, we found that three basic parameters have been mostly studied are speed, feed and DOC. We are going to take a one parameter material?s initial temperature which is not studied much more as that of first three parameters. For investigation, full factorial approach has been used, by taking L16 array. This approach has been applied to investigate the maximize values of the cutting process in end milling for Al 6061 alloy in order to provide better surface finish. With the help of full factorial approach, by performing experiments it has been found that surface finish has gets affected by material?s initial temperature. Graphs and response table were used to find the effect of parameters in end milling process. Also, we are getting the mathematical model for Ra value with the help of regression analysis. The Ra value is getting 14% affected by reducing Material?s initial temperature.

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