Prediction of Improved Surface Quality by Optimized Influential Milling Processes Parameters with Different Cutters on Magnesium Alloy

The present study examines the impact of various milling process parameters on the production of a high-quality surface for the magnesium alloy AZ61, which contains 1% zinc and 6% aluminum. The most important output of any kind of subtractive manufacturing process is surface roughness. The experimental work focuses on the surface roughness (Ra)of AZ61alloy during milling using two different cutters HSS and Carbide. A powerful statistical technique Taguchi design of experiments is utilized with three levels of cutting speed (Vs), feed rate (Fr) and depth of cut (Dc). The experiments are conducted with L9 orthogonal array and the surface roughness values are recorded. An ANNOVA is conducted with both the input and output response having a 95% confidence level. Experimental results showed that the Carbide tool outperforms the HSS tool at High Speed (1000 rpm), high feed Rate (21.5 mm/min), and medium depth of Cut (1 mm).