Dry Milling Machining: Optimization of Cutting Parameters Affecting Surface Roughness of Aluminum 6061 using the Taguchi Method

In this paper, the application of dry machining as part of contributions for development of a sustainable environment in the machining industry is explained. Achieving a good surface roughness product is one the most important factors that must be considered in the metal machining process. Surface quality control is a complicated process, and a reliable technique is required during machining operation. Currently, an appropriate cutting conditions in most of machining cases are determined by trial and error, which leads to time increased, energy consumption, and manufacturing costs. Most of the previous studies have investigated factors that affect surface roughness, but different machining conditions require the control of different factors. In this study, experiments were conducted to optimize cutting parameters and determine the factors significant for the surface roughness quality. Machining experiments were conducted on a vertical milling machine using square non-coated two flutes HSS Co end mill with selected cutting parameters on aluminum 6061. This study focused on the surface roughness in one direction and combined with the Taguchi design method. Signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were employed to examine and reveal the factors that are significant in affecting surface roughness quality. The analysis result revealed that cutting speed exerts the highest effect on surface roughness, followed by feed rate and depth of cut. Finally, the combination of dry machining performance and an eco-friendly environment would result in competitive sustainable growth of the machining industry.