Optimization of milling process parameters of aluminium alloy LM6 using response surface methodology

Abstract

This paper discusses the use of response surface methodology (RSM) for maximizing Metal Removal Rate (MRR) and minimizing Surface Roughness (Ra) in machining LM6 alloy material. The levels of three machining parameters spindle speed, feed rate and depth of cut are optimized during end milling operation. RSM is used for this experimentation. The regression models are developed and effect of each parameter on MRR and Ra is identified through the regression models. The results are analyzed through response surface and contour plots. The significant parameters are identified through Analysis of Variance (ANOVA) for MRR and Ra; all three parameters are significant for MRR, whereas spindle speed and feed rate are significant for Ra. Response surface optimization shows that the milling parameters are 2550RPM, 0.202mm/rev and 1mm for spindle speed, feed rate and depth of cut respectively. The maximum value for MRR is 0.043kg/min and that for surface roughness is 2.007μm at optimal parameter levels.