Influence Of Milling Parameters On Surface Roughness Of 6061 Aluminum Alloy Based On Response Surface Methodology

By the automobile manufacturing industry rapidly developed,the production of auto parts directly affect the development of the automobile industry,cylinder and cylinder head are core and basic parts of the engine.Therefore,Engine cylinder and cylinder head manufacturing level has a crucial effect in a country's automobile manufacturing level.In the context of energy saving and emission reduction worldwide,the fuel economy of automobiles is more and more concerned by the manufacturers.Aluminum engine application promote the realization of energy-saving emission reduction.6061 aluminum alloy with its high tensile strength,corrosion resistance,fatigue resistance and other mechanical properties,becomes the ideal structural materials.it is widely used in mechanical parts,aircraft fuselage materials and aviation industry,etc..Most of the automobile engine block aluminum alloy material to reduce their weight.As the engine block is sealed,the cylinder head and other surface processing quality requirements are high.Surface roughness is one of the important indexes to judge the surface quality of cutting,so it requires to measure the surface roughness to ensure that the workpiece processing quality can meet the technological requirements and to guide the experiment by the prediction results.In the production process,the cutting parameters has an important impact on the surface roughness and processing efficiency.Therefore,screening reasonable processing parameters is conducive to improving the processing surface quality and processing efficiency.In this study,6061 aluminum alloy is selected to perform the cutting simulation test,and test results and analytical methods are researched.The main contents and achievements are as follows:(1)Orthogonal regression test protocol is designed by Matlab and Design-Expert,workpiece and tool model are seted up by the DEFORM-3D.High speed milling 6061 aluminum alloy is performed simulation analysis to observe the surface quality and measure,filter,calculate the surface roughness values.(2)The relationship between the surface roughness and the cutting parameter relation model is fitted by orthogonal regression method and surface response method respectively to get numerical relationship between surface roughness and cutting parameters.The variance analysis and significance test are performed on the twomodels,then my paper compare the differences between the two methods to get the pros and cons.The results are follows: The surface response method has better fitting effect,higher confidence and practicability.It is suitable for the prediction,optimization and control of surface roughness.(3)According to the surface response method,the influence of cutting parameters on the surface roughness is analyzed.Combined with the material removal rate,under the premise of processing surface quality and processing efficiency,the order of the roughness of the cutting parameters and the optimal combination is obtained,The test results are verified by the cutting test finally.