Tribology and Materials | Volume 4 | Issue 1 | 2025 | 9-17
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https://doi.org/10.46793/tribomat.2025.004
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Analysis of 3D surface roughness in trochoidal milling of AA 6082 aluminium alloy
Nikolaos A. Fountas
1,
Rafał Kudelski2,
Nikolaos M. Vaxevanidis
1
1 School of Pedagogical and Technological Education, Athens, Greece
2 Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Kraków, Poland
Abstract: This research examines the effect of trochoidal milling
strategy parameters, namely cutting speed (Vc), feed per tooth (fz) and
trochoidal step (Ptr) on arithmetical mean height (Sa), maximum height
(Sz) and the functional volume parameters, namely peak material volume
(Vmp) and core material volume (Vmc). As a working material for
trochoidal milling, the AA 6082 aluminium alloy was selected. By
assigning three levels for machining parameters, an L9 Taguchi
orthogonal array was adopted to design and conduct the experiments. The
effects of trochoidal milling parameters on the responses were examined
through analysis of variance (ANOVA), contour plots and 3D topographic
analysis maps. Reliable regression models were generated to correlate
the independent variables with the surface quality responses. The
results revealed that significant differences are indicated regarding
the hierarchy effect of trochoidal milling parameters on surface and
functional volume indicators. For arithmetic mean height Sa, feed per
tooth is the dominant parameter, followed by trochoidal step and cutting
speed. Maximum height Sz exhibits a different hierarchy in terms of the
main effects of cutting parameters. Cutting speed has the most
significant effect followed by feed per tooth and trochoidal step. The
dominant parameter for peak material volume Vmp is feed per tooth,
followed by trochoidal step and cutting speed. In the case of core
material volume Vmc, the feed per tooth is the most significant milling
parameter, followed by the effects of trochoidal step and cutting speed.
Keywords: surface roughness, 3D functional volume, trochoidal milling, AA 6082, regression analysis.
Received: 18-12-2024, Revised: 16-01-2025, Accepted: 30-01-2025
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International (CC BY-NC 4.0) license, which allows users to distribute, remix, adapt,
and build upon the material in any medium or format for non-commercial purposes only, and only so long as attribution is given to the creator.
2 Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Kraków, Poland
Abstract: This research examines the effect of trochoidal milling strategy parameters, namely cutting speed (Vc), feed per tooth (fz) and trochoidal step (Ptr) on arithmetical mean height (Sa), maximum height (Sz) and the functional volume parameters, namely peak material volume (Vmp) and core material volume (Vmc). As a working material for trochoidal milling, the AA 6082 aluminium alloy was selected. By assigning three levels for machining parameters, an L9 Taguchi orthogonal array was adopted to design and conduct the experiments. The effects of trochoidal milling parameters on the responses were examined through analysis of variance (ANOVA), contour plots and 3D topographic analysis maps. Reliable regression models were generated to correlate the independent variables with the surface quality responses. The results revealed that significant differences are indicated regarding the hierarchy effect of trochoidal milling parameters on surface and functional volume indicators. For arithmetic mean height Sa, feed per tooth is the dominant parameter, followed by trochoidal step and cutting speed. Maximum height Sz exhibits a different hierarchy in terms of the main effects of cutting parameters. Cutting speed has the most significant effect followed by feed per tooth and trochoidal step. The dominant parameter for peak material volume Vmp is feed per tooth, followed by trochoidal step and cutting speed. In the case of core material volume Vmc, the feed per tooth is the most significant milling parameter, followed by the effects of trochoidal step and cutting speed.
Keywords: surface roughness, 3D functional volume, trochoidal milling, AA 6082, regression analysis.
Received: 18-12-2024, Revised: 16-01-2025, Accepted: 30-01-2025
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International (CC BY-NC 4.0) license, which allows users to distribute, remix, adapt, and build upon the material in any medium or format for non-commercial purposes only, and only so long as attribution is given to the creator.