Determination of Optimum Machining Condition for Surface Roughness Using Historical Data

  • Authors

    • Mohd Shahfizal Mohd Ruslan
    • Haniff Abdul Rahman
    • Jaharah Abdul Ghani
    • Che Hassan Che Haron
    • Mohd Shahir Kassim
    • Kamal Othman
  • AZ91D, Dry Cutting, High Speed Machining, Historical Data, Optimize, Response Surface Method, Surface Roughness
  • Magnesium alloy is one of the lightest materials with a high strength to weight ratio and excellent machinability, which makes it attractive and suitable for various industrial applications such as automotive and aerospace components. For these particular industrial components, the end products require a mirror-like finish. This article details a statistical analysis about the effect of milling parameters on the surface roughness of Magnesium alloy AZ91D in the dry milling process. The historical data approach in the response surface methodology (RSM) was utilized to determine the cause and effect relationship between the input variables and output response. The effect of milling parameter studied was cutting speed (900 – 1400 m/min), feed rate (0.03 - 0.09 mm/tooth), and radial depth of cut (0.2 - 0.3 mm). The results confirmed that the interaction between feed rate and cutting speed is the primary factor controlling the surface evolution. The responses of various factors were plotted using a two-dimensional interaction graph and the cubic empirical model was developed at 95% confidence level. The optimum condition for achieving the minimum surface roughness was a cutting speed of 977 m/min, a feed rate of 0.02 mm/tooth, and an axial depth of cut of 0.29 mm. With this optimum condition, a surface arithmetic roughness of 0.054 μm is expected. This study confirmed that by milling AZ91D at high speed cutting, it is possible to eliminate the polishing process to achieve a super mirror-like finishing.

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  • How to Cite

    Ruslan, M. S. M., Rahman, H. A., Ghani, J. A., Haron, C. H. C., Kassim, M. S., & Othman, K. (2018). Determination of Optimum Machining Condition for Surface Roughness Using Historical Data. International Journal of Engineering & Technology, 7(4.30), 73-75.