Machinability Study of Aluminium 6061 Alloy on End Milling Process

Usage of non-ferrous materials is increasing day-by-day due to its wide variety of applications in many areas because of their properties, availability etc. Hence the study and development of these materials in many aspects is increasing. Of all the non-ferrous metals, Aluminium is one of the most widely used metal. This paper focuses on casting of Al6061 alloy by varying the composition of its alloying elements and also to study the machinability properties of Al 6061 by conducting set of experiments on Al-6061 alloy under vertical milling machine using HSS end mill cutter and finding out the output responses, Metal removal rate, Surface finish, and Cutting forces by varying process parameters speed, feed and depth of cut. Response Surface Methodology (RSM) and Full Factorial Design of Experiments were used to develop the regression equation between input parameters and output responses. Contribution of each factor (Speed, Feed and Depth of Cut) on output parameters (Metal removal rate, Surface finish, and Cutting Force) was determined using ANOVA.