Experimentation of Adaptive Strategies in High-Speed Machining (HSM) for Rough Milling Process Using Prodax Aluminum

Abstract

In this project, the rough milling mechanized process was carried out without cutting fluid to analyze their performance. It compared conventional and adaptive strategies in high-speed machining (HSM). The material tested was a 7075-76 aluminum alloy (Prodax aluminum) because of the excellent mechanical properties and the high scope to use in molds and dies. Machining time and tool temperature were measured by varying cutting parameters, such as cutting speed (Vc) and feed per tooth (fz). The conventional strategy was performed with a constant cutting depth of 2,188 mm and a cutting width of 64% in diameter. Similarly, the adaptive strategy was done with a constant cutting depth of 14 mm and a cutting width of 10% in diameter. The milling tool was an HSS straight with 4 flutes and with 25 mm in diameter. A Taguchi experimental methodology L32 (2 ^ 1 4 ^ 2) was applied to combine parameters and levels; therefore, 16 tests were carried out for each strategy. Furthermore, an ANOVA statistical analysis determined that the adaptive strategy has the lowest machining time in comparison with the conventional strategy. As a maximum success, a machining time reduction of 82.3% was reached.