Experimental Studying and Optimization of Cutting Parameters in CNC Turning of AA7076 Aluminum Alloy

Abstract

The Important Measure Of Quality In Machining Is Surface Roughness And It Is Usually Difficult To Obtain Low Surface Roughness During Turning Of Aluminum Alloys Due To Their High Ductility Property. This Study Is Mainly Focused On Optimization Of Cutting Parameters (Feed Rate, Depth Of Cut And Spindle Speed) For Good Surface Finish And Higher Material Removal Rate During Computer Numerical Control (Cnc) Turning Of Aa7076. The Experiments Were Performed By Using Uncoated Carbide Insert And New Cutting Insert Was Used For Each Test. Taguchi L9 Was Selected For Design Of Experiment. Taguchi Analysis Of Signal-To-Noise Ratio And Analysis Of Mean Were Used To Optimize Cutting Parameters. Analysis Of Variance (Anova) Was Used To Determine The Influence Of Cutting Parameters On Surface Roughness And Material Removal Rate. The Chips Were Characterized Based On The Iso Chip Classification And The Influence Of Cutting Parameters On Chip Thickness And Width Was Also Analyzed. The Optimum Cutting Parameter Combination Obtained Was High Spindle Speed (1600 Rpm), Medium Depth Of Cut (1 Mm), And Low Feed Rate (0.08 Mm/Rev). The Minimum Surface Roughness And Optimum Material Removal Rate Obtained At Optimum Condition Were 0.9875 Micrometer And 15682.83 Mm3/Min Respectively. From Anova All Cutting Parameters Were Found To Affect Surface Roughness And Material Removal Rate Significantly. Feed Rate Weight Percentage Of 46.03%, Depth Of Cut Of 29.18% And Spindle Speed 20.52% Found To Have Significant Influence On The Surface Roughness While Depth Of Cut Weight Percentage 54.734%, Spindle Speed 19.164% And Feed Rate 17.473% Found To Have Significant Influence On Material Removal Rate. From Analysis Of Chip Morphology Generally Snarled Tubular, Snarled Ribbon, Washer Type Helical, And Arc Type Chips Were Observed And Chip Thickness Was Found To Increase With Both Feed Rate And Depth Of Cut.