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Experimental Investigation and Optimization of Machining Parameters in

Turning of Aluminum Alloy 075-T651

Article  in  Production Engineering Archives · November 2021

DOI: 10.30657/pea.2021.27.40

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 PRODUCTION ENGINEERING ARCHIVES 2021, 27(4),296-305

PRODUCTION ENGINEERING ARCHIVES

ISSN 2353-5156 (print) Exist since 4th quarter 2013
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Experimental Investigation and Optimization of Machining

Parameters in Turning of Aluminum Alloy 075-T651
Arpit Srivastava1,* , Mukesh Kumar Verma1 , Ramendra Singh Niranjan1 , Abhishek Chandra1 ,
Praveen Bhai Patel1
1 Departmentof Mechanical Engineering, UIET, CSJMU, Kanpur, India, [email protected] (M.K.V);
[email protected] (R.S.N.); [email protected] (A.C.); [email protected] (P.B.P.)
*Correspondence: [email protected]

Article history Abstract

Received 13.06.2021 Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors.
Accepted 13.10.2021 The wide application marks the importance of this material’s research in the manufacturing field. This
Available online 15.11.2021 research focuses on optimizing input process parameters of the turning process in the machining of
Keywords Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting
Taguchi Method speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force,
Feed Force material removal , and surface roughness of the workpiece. For optimization of process parameters,
Cutting Force the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain signifi-
Radial Force cant factors and optimal combinations of process parameters.
MRR

DOI: 10.30657/pea.2021.27.40 JEL: L69, M11

List of Abbreviations
Abbreviations Meanining Unit
MRR Material removal rate mm3/s
Ra Surface roughness µm
DoC Depth of a cut mm
N Cutting speed rpm
𝑓 Feed mm/rev
Feed Force Forces in machining Newton
Radial Force Forces in machining Newton
Cutting forces Forces in machining Newton

1. Introduction on the product's characteristics after turning. Turning can be

carried either on the manual lathe or a CNC lathe .
The turning process is most extensively used in the field of Aluminum Alloy 7075-T651 has several applications in al-
conventional machining. In turning, material removal takes most every field, namely, aviation, marine and automobile.
place through the cutting tool from the rotating workpiece. Mali et al. (2020); experimented with investigating the ef-
In simple straight turning, the feed of the cutting tool is pro- fect of parameters such as speed and depth of a cut on machin-
vided in a parallel direction to the rotation axis of the work- ing forces in turning of Al-7075. Researchers verified experi-
piece. In a turning operation, the lathe machine produces the mental results of the dry turning process of Aluminum 7075
power for rotation of the workpiece with a particular speed, with a Finite Element-based numerical-approach. The results
and provides feed and depth of cut to the cutting tool. Thus, indicated that both the cutting and feed force increase with en-
these input parameters of machining, cutting speed, feed, and hance in feed and depth of a cut. However, the spindle speed
depth of cut are important during t he t urning. It becomes cru- showed the least influence on the forces.
cial for a manufacturer to know the effect of these parameters

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Das et al. (2018); investigated the effect of parameters such Viramgama et al. (2016); investigated that the quality of the
as speed, and depth of a cut on material removal rate in turning machined work surface depended on the shape and size of the
T6 tempered Al 7075 alloy with uncoated tungsten carbide in- chips.
serts in a dry environment. The results indicated that spindle Srivastava et al. (2015) observed the effect of input machin-
speed was the most significant parameter taken after the feed, ing parameters on heat generation during machining of In-
and the influence of depth of cut was insignificant. conel 718. A high depth of a cut produces a greater value of
Ajith kumar et al.(2019); experimented with dry turning of cutting forces and causes more heat generation. If the work-
three hybrid composites, viz. (i) Al7075-10%SiC-0.1% B4C, piece material has lower thermal conductivity, the dissipation
(ii) Al7075-10%SiC-0.1% Graphene, and (iii) Al7075- of heat from the machining zone becomes a challenge.
10%SiC-0.1% CNT using uncoated and Diamond-Like Car- Mishra et al. (2018) experimented and optimized machining
bon (DLC) coated carbide tool. The results indicated that the input parameters in turning of Inconel 718. The authors ob-
feed rate is the most dominant factor influencing the surface served that the most significant factor was the cutting speed,
roughness. followed by the depth of cut and feed in the machining of In-
Junge et al. (2020) investigated the surface properties of conel 718.
Aluminum alloy EN AW-2017 workpiece during the machin- Reddy et al. (2017) investigated machining issues and opti-
ing operation. Researchers used Seebeck effect-based thermo- mized machining parameters in the turning operation of 7075
couples to predict the temperature and cutting tool wear during Aluminum alloy with Taguchi L27 orthogonal array. The re-
the machining. They reported that an increase in temperature sult demonstrated that temperature induced in machining was
caused a rise of voltage and current. most affected by the depth of a cut. Cutting force was affected
Cagen et al.(2020) performed work on the type of chip for- the most by speed, and feed has played the most significant
mation and surface quality of Al7075-T6 alloy workpiece un- role in affecting surface roughness.
der dry and MQL conditions. Results indicated the better sur- Gupta et al. (2015) used the Taguchi-based Grey Relation
face quality of a workpiece with a long segment of chips Analysis for optimizing the machining parameters, namely,
reported under the MQL compared to dry machining. speed, feed, cooling conditions during turning operation of
Singh et al. (2020) studied the milling operation on Al6061 AISI 4340 steel on a Center Lathe machine. Cutting Force,
alloy with MQL condition. To obtain significant input param- tool wear rate and surface roughness were the output parame-
eters to produce a better surface finish of workpiece, ANOVA ters. A tungsten carbide insert was used for machining. L9
was used. Results indicated that the feed has a major contribu- orthogonal arrays were used for optimization purposes. For
tion in determining a better surface finish compared to coolant cooling, three conditions were chosen, namely wet, dry and
flow rate and cutting speed. cryogenic (using liquid nitrogen). They found the cooling
Schindler et al. (2014) investigated the thermo-elastic defor- need as the most significant factor, followed by speed and
mation of the aluminum alloy under dry machining conditions feed. Cryogenic cooling was chosen as the most optimal cool-
with help of a finite element model. The authors concluded ing condition. ANOVA confirmed the results.
that the workpiece temperature depended upon heat flux pro- Makadia et al. (2013) used Response Surface Methodology
duced due to cutting forces and heat dissipation towards the for optimization of machining parameters cutting speed, feed,
surrounding. depth of a cut and nose radius of cutting tool during turning
Sahithi et al. (2019) investigated and optimized parameters of AISI 410 on CNC Lathe. They measured surface roughness
during the turning operation on Aluminum alloy 6061, Alumi- as an output parameter and found the feed to be the most con-
num alloy 6063, and Aluminum alloy 6082 through the Tauchi tributing factor, followed by nose radius. Speed was also
technique. Researchers observed that a better surface finish slightly significant, while the depth of cut was hardly signifi-
was found on Aluminum 6063 than Aluminum 6061 at cutting cant. A regression model was also developed using the RSM.
speed 500 rpm, feed 0.10mm/min, and depth of cut 0.5 mm. ANOVA was used toconfirm the result.
Deepak et al. (2015); experimented with and without cool- Verma et al. (2018) used the Taguchi Method to optimize
ant on AL6061. Researchers reported that the feed-rate was machining forces in turning operation of EN-8 steel on HMT
the most significant factor which affects metal removal rate NH22 lathe .They used L9 orthogonal array for study, and
during machining of Al6061, followed by the depth of cutting found that the percentage involvement of the depth of a cut on
and cutting speed. cutting force and feed force was maximum. The feed was the
Gangopadhyay et al. (2010); studied the two cutting tools; second major contributing factor to both cutting and feed
chemical vapour deposited diamond and polycrystalline dia- forces. Spindle speed was the minor significant factor.
mond cutting tools, and reported that polycrystalline diamond Mishra et al. (2018) optimized the cutting force, feed force,
cutting tools were an excellent tool for aluminum alloys in ma- and MRR in turning of Inconel 718 with coated (TiAlN and
chining under dry environment because of high thermal con- TiN) carbide insert. They used the Taguchi method to opti-
ductivity, low coefficient of friction and elevated temperature. mize the machining force. The study proposes that the cutting
The main problem in aluminum alloys machining with an un- speed is the most influencing factor among input process pa-
coated carbide cemented insert is forming of a built-up layer rameters.
on the rake surface. Dabhi et al. (2016) investigated optimizing the cutting pa-
rameters for the lowest surface roughness gained during the
turning of stainless steel SS410 grade workpiece. Machining

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experiments were performed at the CNC machine using car- 3.2. Cutting Insert
bide cutting tools on SS410 materials. The analysis of variance
estimated the effects of the cutting conditions and cutting tool For the entire experiment, the turning operation was
materials on the surface roughness of a workpiece. The statis- performed using an uncoated tungsten carbide insert with
tical analysis showed that the machining parameters with a specification CNMG120404, as shown in Figure 1. The aim
significant impact on surface roughness were the cutting speed was to study the response when an uncoated insert is used for
trailed by the depth of a cut and feed correspondingly. turning of Aluminum Alloy 7075.
Pandey and Yadav (2020) demonstrated optimization of
process parameters during low-frequency vibration-assisted
electric discharge machining of Ti-6Al-4V and Al-TiB2. They
have presented the effects of vibration of tool electrodes on
process parameters.
Macek et al. (2020) studied variation in fracture surface and
crack profile in loading environments. The authors concluded
that prime crack lengths were found at those conditions, which
was other than B=T. Macek et al. (2021) performed a study on
fracture surfaces of S355J2 steel workpiece at non-propor- Fig. 1. Tungsten Carbide Insert (Uncoated)
tional bending with torsion with 3 D profilometer to investi-
gate surface quantities. The authors promoted this method as 3.3. Selection of Process Parameters
a measurement methodology as well as the technique of sur-
face evaluation. During the experiment, three process parameterswere se-
lected along with their three levels. The preferred process pa-
rameters were cutting speed (rpm), feed rate (mm/rev), and
3. Experimental Details depth of cut (mm). Table 3 shows the selected process pa-
The turning operation was carried out on HMT NH22 lathe rameters with their three-level values.
in Central Workshop at U.I.E.T CSJM University Kanpur. Table 3. Process Parameters and their Levels

3.1. Work Piece Material Factors Unit Level-1 Level-2 Level-2

The selected workpiece for the study was Aluminum Alloy Speed rpm 325 550 715
7075, which was in the form of a cylindrical bar of 300 mm Feed mm/rev 0.08 0.10 0.12
length and 60mm diameter. Table 1 and Table 2 show the Depth ofcut mm 0.1 0.3 0.5
chemical configuration and mechanical properties of Alumi-
num Alloy 7075-T651, respectively. 3.4. Experimental Procedure
Table1. Chemical Configuration of Aluminum Alloy-7075-T651 The entire experiment was performed on an HMT NH22
(ASM International, 1990) lathe, as shown in Figure 2. For the experimental design and
Component Weight%
run order, a commercially available software Minitab18 was
used and experiments were performed accordingly. The dy-
Aluminum 87.1-91.4
namometer used for the force measurement was UIL 15 Lathe
Chromium 0.18-0.28
Tool Dynamometer. For the surface roughness measurement
Copper 1.2-2
Mitutoyo Surftest SJ-201 P/M Portable Surface Roughness
Iron Max 0.5 Tester was used. Both of these instruments were calibrated
Magnesium 2.1-2.9 through manual measurements. Length parameter is 3.2 mm
Manganese Max 0.3 for measuring surface roughness of workpiece.
Silicon Max 0.4
Titanium Max 0.2
Zinc 5.1-6.1
Others Max 0.20

Table 2. Properties of Aluminum Alloy 7075-T651 (ASM Interna-

tional, 1990)
Property Value
Hardness HRB 87
Ultimate Tensile Strength 572 MPa
Tensile Yield Strength 503 MPa
Elongation at Break 11%
Density 2810 kg/m3

Fig. 2. HMT NH22 Lathe

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3.5. Methodology adopted for optimization of 8.58%. The speed is the least significant with a percentage
contribution of 3.68%. The S/N ratio is an essential character-
For optimization, the Taguchi Method was employed. The- istics of the Taguchi Method. It takes into account both the
Taguchi method is a statistical procedure developed to in- magnitude as well as variation in response. No matter what
crease the product quality.Taguchi defined the product quality type of response, the highest value of the S/N ratio corre-
in terms of minimum loss to society. The method makes use sponds to a better response. Hence the factor levels corre-
of a robust design strategy by using specially designed arrays spond the to the highest S/N ratio are termed as optimal. Fur-
called orthogonal arrays, which make use of a few experi- ther S/N ratio is found higher for those responses which
mental trials against the full factorial design. Taguchi method have the highest average value or lowest average value
makes the process insensitive to noise factors through the (whichever is applicable). Those can be easily seen from the
use of the S/N ratio, which also helps to analyze results easier. direct effects plots. For the feed force, the lower mean value
Its biggest drawbackis that it usually neglects interactions is desired and chosen, the better critera are achieved int terms
of the S/N ratio. It is seen from Figures 3 and 4 that the optimal
4. Result and Discussion combination of parameters for the feed forceis the speed at
715 rpm (main effect plot here gives a better picture), feed at
4.1. For the Taguchi Method
0.08 mm/rev and depth of a cut at 0.1 mm. It is seen from
The experimental design and analysis of experimental data figure 3 that as the speed is increasing from 325 to 715 rpm,
for the entire experiment were done using the statistical soft- the feed force is decreasing continuously. In the entire exper-
ware Minitab18. For the present work, the L9 orthogonal ar- imental region, the heat dissipation rate is dominant over the
ray (OA) of Taguchi was used. Three sets of experiments strain hardening and the thermal softening results in a de-
were carried out. It helped to better predictions and accurate crease in the force. Further, increasing the feed or the depth
results. Table 4 shows the three sets of experiments. From Ta- of a cut, the feed force is rising due to the increased friction
ble 5, it is clear that all the three parameters, cutting speed, of heavier chips.The delta values in Tables 6 and 7 confirm
feed, and depth of a cut, are significant factors in affecting the results.
t h e feed Force.
A significant factor with a contribution of 83.99%. The feed
is the next significant factor with a percentage contribution
Table 4. Experimental Results for Taguchi Method
Exp. Cutting Feed Depth of Feed Cutting Radial MRR (Ra) Surface
(SET 1) speed (mm/rev) cut(mm) Force Force (N) Force(N) Roughness
(rpm) (N) (mm3/s) (µm)
1 325 0.08 0.1 9.81 19.62 29.43 8.13 0.81
2 325 0.10 0.3 49.05 68.67 39.24 34.17 0.79
3 325 0.12 0.5 98.10 117.72 19.62 67.06 1.13
4 550 0.08 0.3 39.24 58.86 19.62 46.65 0.70
5 550 0.10 0.5 78.48 88.29 19.62 94.97 0.92
6 550 0.12 0.1 29.43 49.05 39.24 23.52 0.98
7 715 0.08 0.5 68.67 88.29 9.81 95.45 0.82
8 715 0.10 0.1 19.62 49.05 39.24 25.08 0.74
9 715 0.12 0.3 49.05 58.86 29.43 90.08 0.90
Exp. Cutting Feed DoC Feed Cutting Radial MRR (Ra) Surface
speed Force Force (N) Force(N) Roughness
(SET 2) (rpm) (mm/rev) (mm) (N) (mm3/s) (µm)
1 325 0.08 0.1 9.81 19.62 29.43 8.06 0.97
2 325 0.10 0.3 58.86 78.48 39.24 33.97 0.92
3 325 0.12 0.5 107.91 156.96 29.43 64.88 0.95
4 550 0.08 0.3 49.05 58.86 19.62 45.79 0.94
5 550 0.10 0.5 78.48 78.48 19.62 93.16 0.89
6 550 0.12 0.1 29.43 58.86 39.24 23.09 0.87
7 715 0.08 0.5 58.86 78.48 9.81 92.89 0.79
8 715 0.10 0.1 19.62 49.05 29.43 24.26 0.83
9 715 0.12 0.3 49.05 68.67 29.43 86.94 0.80
Exp. Cutting Feed DoC Feed Cutting Radial MRR (Ra)Surface
speed Force Force (N) Force(N) Roughness
(SET 3) (rpm) (mm/rev) (mm) (N) (mm3/s) (µm)
1 325 0.08 0.1 9.81 19.62 29.43 8.20 0.88
2 325 0.10 0.3 58.86 78.48 39.24 33.20 0.87
3 325 0.12 0.5 98.10 117.72 19.62 66.07 1.05
4 550 0.08 0.3 49.05 58.86 19.62 46.05 0.74

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5 550 0.10 0.5 78.48 78.48 19.62 93.73 0.88

6 550 0.12 0.1 29.43 58.86 39.24 22.87 0.89
7 715 0.08 0.5 68.67 68.67 19.62 98.56 0.92
8 715 0.10 0.1 19.62 39.24 39.24 24.26 0.75
9 715 0.12 0.3 49.05 68.67 29.43 88.96 0.95
Table 5. Analysis of Variance for Feed Force
Source DoF Seq SS Contribution Adj SS Adj MS F-Value P-Value
Speed 2 5174 3.68% 5174 2586.8 9.80 0.01
Feed 2 12054 8.58% 12054 6027.0 22.82 0.00
DoC 2 118048 83.99% 118048 59023.8 223.51 0.00
Error 20 5282 3.76% 5282 264.1
Total 26 140 100
557 %

Table 6. Response for Means for Feed Force Table 7. Response for the S/N ratio for feed force (smaller is better)
Level Speed Feed Depth of a cut Level Speed Feed Depth of a cut
1 55.59 40.33 19.62 1 -31.63 -29.81 -25.02
2 51.23 51.23 50.14 2 -33.51 -32.89 -34.00
3 44.69 59.95 81.75 3 -32.00 -34.44 -38.12
Delta 10.90 19.62 62.13 Delta 1.88 4.63 13.10
Rank 3 2 1 Rank 3 2 1

Fig. 3. Effect of Process Parameters on the feed force - raw data

Fig. 4. Effect of Process parameters on the feed force - S/N ratio
It is clear from Table 8 that all the three process parameters similarly. Further, it is seen that error contributes to about
are significant for the cutting force. It is seen that the depth of 16.66% to response which means that either interaction effect
cut is the most significant, with a contribution of 61.22%. The is also significant here, or that there is one or more process
feed is next significant with a contribution of 19.01% , while parameter that are not taken into account From Figure 5 and
the speed is the least significant with a contribution of 3.10%. 6 it is clear that the optimal settings for the cutting force is
The behavior of Cutting force in Fig. 5 and 6 with process speed at 715 rpm, feed rate at 0.08 mm/rev and depth of cut
parameters are the same as of the feed force and are explained at 0.1mm.

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Table 8. Analysis of Variance for the cutting force

Source DoF Seq SS Contribution Adj SS Adj MS F-Value P-Value

Speed 2 734.2 3.10% 734.2 367.12 1.86 0.181
Feed 2 4498.1 19.01% 4498.1 2249.07 11.41 0.000
DoC 2 14485.3 61.22% 14485.3 7242.66 36.75 0.000
Error 20 3942.1 16.66% 3942.1 197.11
Total 26 23659.8 100.00%

Table 10. Response for the S/N ratio of the cutting force (Smaller
Table 9. Response for Means for the cutting force the better)
Level Speed Feed DoC Level Speed Feed Depth of Cut
1 75.21 52.32 40.33 1 -29.54 -26.02 -30.81
2 65.40 67.58 66.49 2 -27.86 -29.64 -29.03
3 63.22 83.93 97.01 3 -27.80 -29.54 -25.35
Delta 11.99 31.61 56.68 Delta 1.74 3.62 5.36
Rank 3 2 1 Rank 3 2 1

Fig. 5. Effect of process parameters on the cutting force - raw Fig. 6. Effect of process parameters on the cutting force- S/N ratio
data
It is clear from Table 11 that all the three process parame- be interaction or an unconsidered process parameter. From
ters are significant for the radial force. Depth of a cut is the Figure 7, the behaviour of the radial force due to speed and is
most significant with a contribution of 53.85%. The feed is explained similarly as for the feed force and cutting force. It
next significant factor with a contribution of 28% and the is seen that the feed force increases initially up to 0.10 mm/rev
speed is next significant factor with a contribution of 4.92%. feed due to dominant friction in shearing the material and in
Error contributes 13.23% to the response indicating the de- chip removal.
pendence of the radial force on any other factor, which may
Table 11. Analysis of Variance for the radial force
Source DF Seq SS Contribution Adj SS Adj MS F-Value P-Value
Speed 2 114.1 4.92% 114.1 57.03 3.72 0.042
Feed 2 648.7 28.00% 648.7 324.35 21.16 0.000
DoC 2 1247.5 53.85% 1247.5 623.75 40.70 0.000
Error 20 306.5 13.23% 306.5 15.33
Total 26 2316.8 100.00%

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Beyond this, the radial force tends to decrease. Further, it is Figure 7 and 8 that the optimal combination for the radial
seen radial force is decreasing continuously with the depth of force is the speed at 715 rpm, feed rate at 0.08 mm/rev, and
cut. Both these may be due to the fact that there is excess ther- depth of cut at 0.5 mm.
mal softening, which is the most dominant. It is clear from
Table 13. Response for the S/N ratio for the radial force (Smaller
Table 12. Response for Means for the radial force the better)
Level Speed Feed DoC Level Speed Feed DoC
1 30.52 20.71 34.88 1 -29.54 -26.02 -30.81
2 26.16 31.61 29.43 2 -27.86 -29.64 -29.03
3 26.16 30.52 18.53 3 -27.80 -29.54 -25.35
Delta 4.36 10.90 16.35 Delta 1.74 3.62 5.46
Rank 3 2 1 Rank 3 2 1

Fig. 7. Effect of process parameters on the radial force - raw data Fig. 8. Effect of process parameters on the radial force – S/N ratio

Table 12. Analysis of Variance for the MRR

Source DF Seq SS Contribution Adj SS Adj MS F-Value P-Value

Speed 2 3.1382 19.07% 3.1382 1.56909 2700.27 0.000
Feed 2 0.8909 5.41% 0.8909 0.44544 766.57 0.000
DoC 2 12.4137 75.44% 12.4137 6.20685 10681.46 0.000
Error 20 0.0116 0.07% 0.0116 0.00058
Total 26 16.4544 100.00%

For the MRR, it is observed that the depth of a cut is the MRR increases with the increment of any factor, which is the
most significant with a contribution of 75.44% followed by most likely because of more material being removed at the
speed which makes a contribution of 19.07% according to ta- same time. It is seen that the optimal combination for MRR
ble 12. The feed is the least significant with only 5.41% con- (which is larger the better type) is the speed at 715 rpm, feed
tribution. Error contribution is negligible indicating absence rate at 0.12 mm/rev, and depth of cut at 0.5 mm.
of any other factor. From Figures 9 and 10 it is clear that the

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Table 14. Response for the S/N ratio for the MRR (larger the bet-
Table 13. Response for means for the MRR ter)
Level Speed Feed DoC Level Speed Feed DoC
1 35.97 49.98 18.61 1 28.39 30.36 24.43
2 54.43 50.76 56.20 2 33.35 32.61 34.27
3 69.61 59.27 85.20 3 35.45 34.21 38.48
Delta 33.64 9.30 66.59 Delta 7.06 3.85 14.05
Rank 2 3 1 Rank 2 3 1

Fig. 9. Effect of process parameters on the MRR – raw data Fig. 10. Effect of process parameters on the MRR – S/N ratio
From Table 15 it is observed that all the three parameters error contribution is high on surface roughness with a contri-
are statistically significant. The feed is the most significant bution of 41.25%, indicating that there are more significant
factor with 26.60% contribution;speed is the next significant factors that should have been taken into account. Tool nose
factor with 17.74% contribution and depth of a cut is the next radius can be such a factor.
significant with a contribution of 14.41%. It is also visible that
Table 15. Analysis of Variance for the surface roughness
Source DF Seq SS Contribution Adj SS Adj MS F-Value P-Value
Speed 2 0.12088 17.74% 0.12088 0.06044 4.30 0.028
Feed 2 0.18128 26.60% 0.18128 0.09064 6.45 0.007
DoC 2 0.09824 14.41% 0.09824 0.04912 3.49 0.050
Error 20 0.28115 41.25% 0.28115 0.01405
Total 26 0.68156 100.00%

Table 17. Response for the S-N ratio for the surface rough-
Table 16. Response for means for the surface roughness ness
Level Speed Feed DoC Level Speed Feed DoC
1 0.9300 0.8411 0.8578 1 0.6415 1.4726 1.3392
2 0.8678 0.8433 0.8456 2 1.2189 1.4867 1.4282
3 0.8333 0.9467 0.9278 3 1.5793 0.4805 0.6723
Delta 0.0967 0.1056 0.0822 Delta 0.9379 1.0062 0.7559
Rank 2 1 3 Rank 2 1 3

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From the Taguchi method, it is observed that:

• For the feed force, depth of a cut is the most significant
factor with 83.99% contribution followed by the feed
rate with a contribution of 8.58% while the speed is the
least significant with 3.68% contribution, while error
only contributes 3.76%. For the feed force the optimal
setting is the speed at 715 rpm, feed rate at 0.08
mm/rev, and cut at 0.1 mm.
• For the cutting force, the depth of a cut is the most sig-
nificant with 61.22% contribution followed by the feed
rate with 19.01% contribution. The speed is the least
significant with 3.10% contribution, while error con-
tributes about 16.66%, which calls for some more sig-
nificant factor or interaction not considered in this
study. For the cutting force the optimal setting is the
speed at 715 rpm, feed rate at 0.08 mm/rev, and depth
of a cut at 0.1 mm.
• For the radial force, the depth of cut is the most signif-
Fig. 11. Effect of process parameters on the surface icant with a contribution of 53.85%, followed by the
roughness – raw data feed with 28% contribution. The speed is the next sig-
nificant factor with a contribution of 4.92%, while error
also contributes about 13.23% , which calls for consid-
ering either interactions or a new factor. For radial force
the optimal setting is the speed at 715 rpm, feed rate at
0.08 mm/rev, and depth of a cut at 0.5 mm.
• For the MRR, depth of a cut is the most significant fac-
tor with a contribution of 75.44% followed by speed,
which contributes 19.07%. The feed rate is the next sig-
nificant factor with 5.41% while error contribution is
negligible. For the MRR, the optimal setting is the
speed at 715 rpm, feed rate at 0.12 mm/rev, and depth
of a cut at 0.5 mm.
• For the surface roughness, the feed is the most signifi-
cant factor with the contribution of 26.60%, followed
by the speed with 17.74% contribution. Depth of a cut
is the least significant with a contribution of 14.41%.

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7075-T651 铝合金车削加工参数试验研究及优化
關鍵詞 摘要
田口法 7075-T651 铝合金是航空、船舶、汽车等领域广泛使用的材料。 广泛的应用标志着该材料研究
进给力 在制造领域的重要性。 本研究工作的重点是优化使用碳化钨刀片加工 7075-T651 铝的车削工
切削力 艺的输入工艺参数。 输入加工参数为切削速度、进给和切削深度，输出响应参数为工件切削
径向力 力、进给力、径向力、材料去除率和表面粗糙度。 为优化工艺参数，使用具有标准 L9 正交阵
MRR 列的田口方法。 应用方差分析来获得重要因素和工艺参数的最佳组合。

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