Cutting Parameters Effects on Surface Roughness During End Milling of Aluminium 6061 Alloy Under Dry Machining Operation

In this project an experimental investigation of the cutting parameters effects on surface roughness during end milling of aluminium 6061 under dry machining operation was carried out. The experiments were carried out to investigate surface quality of the four machined parameters and to developed mathematical models using least square approximation techniques. Spindle speed (N), axial depth of cut (a) radial depth of cut (r) and feed rate (f), has been chosen as input variables in order to predict surface roughness. The experiment was designed by using central composite design (CCD) in which 30 samples were run in a CNC milling machine. Each of the experimental result was measured using Press-o-firm and Mitutoyo surface tester. After the predicted surface roughness values have been obtained the average percentage errors were calculated. The mathematical model developed by using least square approximation method shows accuracy of 91 % which is reasonably reliable for surface roughness prediction. With the obtained optimum input parameters for surface roughness, production operations will be enhanced.