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<p>The growing demand for high-precision components in sectors, such as electronics and biomedicine, has intensified the need for optimized micromachining processes. In this context, this study investigates how cutting speed and feed per tooth influence the surface quality and burr formation in the micro-milling of Al6101 aluminum alloy. The research aims to determine optimal parameter ranges that minimize surface roughness and burr formation. Micro-slots were machined under two test sets: one varying cutting speed (3.5 to 7.5&#xa0;m/min) at constant feed, and another varying feed per tooth (5 to 15&#xa0;µm/tooth) at constant speed, allowing independent analysis of each parameter. Surface quality was assessed using roughness parameters (Ra, Rq, Rz, Rsk, and Rku), and burr heights were measured on both up- and down-milling sides. Results showed that the highest cutting speed (7.5&#xa0;m/min) produced the poorest surface finish due to increased material deformation. In contrast, a lower feed per tooth (5&#xa0;µm/tooth) resulted in improved roughness. All tests showed Rsk &lt; 0 and Rku ≈ 3, indicating valley-dominant surfaces with Gaussian peak distribution. Burrs were consistently higher on the down-milling side due to lack of momentum and material accumulation. </p>

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Contribution to parameter selection for surface quality enhancement in micro-milling of the aluminum alloy Al 6101

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Felipe Alves Sforcini,
  • Geovanna Diniz Mendonça,
  • Maria Clara Coimbra Goncalves,
  • Lucival Malcher,
  • Aline Gonçalves dos Santos,
  • Maksym Ziberov,
  • Déborah de Oliveira

摘要

The growing demand for high-precision components in sectors, such as electronics and biomedicine, has intensified the need for optimized micromachining processes. In this context, this study investigates how cutting speed and feed per tooth influence the surface quality and burr formation in the micro-milling of Al6101 aluminum alloy. The research aims to determine optimal parameter ranges that minimize surface roughness and burr formation. Micro-slots were machined under two test sets: one varying cutting speed (3.5 to 7.5 m/min) at constant feed, and another varying feed per tooth (5 to 15 µm/tooth) at constant speed, allowing independent analysis of each parameter. Surface quality was assessed using roughness parameters (Ra, Rq, Rz, Rsk, and Rku), and burr heights were measured on both up- and down-milling sides. Results showed that the highest cutting speed (7.5 m/min) produced the poorest surface finish due to increased material deformation. In contrast, a lower feed per tooth (5 µm/tooth) resulted in improved roughness. All tests showed Rsk < 0 and Rku ≈ 3, indicating valley-dominant surfaces with Gaussian peak distribution. Burrs were consistently higher on the down-milling side due to lack of momentum and material accumulation.