The Influence of Cutting Parameters on Surface Roughness in Aluminum Alloy Al5083

Aluminum alloys are the most usable material in industrial markets such as aerospace, marine, and automotive due to their excellent performance in resisting fatigue and corrosion. However, once it comes to the machining and particularly the drilling process, the quality of the drilled hole should be considerable to investigate the effect of cutting parameters, namely spindle speed and feed rate, on the inner surface of these holes, where they play a crucial role in many industrial areas. For instance, an aircraft’s wing requires namouras holes to be attached to the main structure by using rivets and bolts. The current paper examines the influence of cutting parameters (feed rates and spindle speed) on surface roughness in aluminum alloy Al5083 by using HSS drill bits. A CNC machine was utilized for the drilling process, where 48 holes were drilled without using any coolant and 48 holes under flooded cutting fluid. The experimental results revealed that both Ra and Rz increased by increasing the spindle speed and feed rate. However, the drilled holes with coolant have minimum Ra and Rz. The optimal parameters for better surface roughness were n = 1000 rpm and f = 100 mm/min in wet conditions. The results were supported by using the full factorial method and ANOVA (analysis of variance) to evaluate each input parameter’s contribution to the hole’s quality, which conclude that the optimal surface roughness is at lower levels of cutting parameters and in a wet environment which play a crucial role in reducing surface roughness with contributions 49% and 50% for both Ra and Rz, respectively, followed by feed rate and spindle speed with minimal contributions.