A box behnken design approach for parametric optimization in processing of aluminum 6061 tubes

In this paper, bonded magnetic abrasives-based media were applied in magnetic field-assisted abrasive flow machining (MFAAFM) for the processing of aluminum 6061 material tubes to improve the surface quality. The effects of different parameters including magnetic field strength (300, 450, 600 mT), number of working cycles (15, 20, 25), and hydraulic pressure (30, 45, 60 bars) on surface roughness improvement rate (SRIR) were studied, and optimization was done utilizing the response surface methodology technique. A Box–Behnken design (BBD) was employed to maximize the SRIR, which was taken as a response variable. A maximum SRIR (72.2%) was attained when the aluminum 6061 tubes was processed at 450 mT of MFS, 25 working cycles, and 60 bars of hydraulic pressure. The model is well fitted and represented utilizing 2nd order polynomial equations. Furthermore, the model validation revealed a 99.84% fit among the actual and experimental values. The surface roughness (Ra) = 0.20 μm of the aluminum 6061 tube samples can be obtained, and the surface morphology after finishing has been greatly improved as revealed by SEM micrographs and Ra peak-valley diagram.