Authors:
Harvinder Singh, Satish Kumar, Rahul Mehra, C. Satheesh, Yuri Ryagin

Addresses:
Department of Mechanical Engineering, Chandigarh Engineering College, Mohali, Punjab, India. Department of Robotics and Automation, Dhaanish Ahmed College of Engineering, Chennai, Tamil Nadu, India. Department of Low Temperature Physics and Nanoscale Systems, Ural Federal University (UrFU), Ural Federal, Sverdlovsk Oblast, Russia.

Abstract:

This study presents the optimization of surface roughness (Ra) in the dry milling of non-ferrous aluminum alloy 6061 (Al-6061) for sustainable manufacturing applications. Experiments were performed on a HYTECH CNC vertical machining center using TiN-coated carbide inserts. The Taguchi L27 orthogonal array was employed to systematically vary cutting velocity, feed per revolution, and depth of cut. Surface roughness was measured for each experimental run, and the results were analyzed using the Taguchi signal-to-noise (S/N) ratio approach and analysis of variance (ANOVA). Scanning electron microscopy (SEM) was utilized to examine the microstructural features associated with surface quality. The optimal combination of parameters—cutting velocity of 600 m/min, feed per revolution of 0.20 mm/rev, and depth of cut of 0.50 mm—produced the minimum average surface roughness of 0.253 µm. ANOVA revealed that feed per revolution exerted the greatest influence on Ra (48.82%), followed by cutting velocity (38.13%) and depth of cut (11.27%). Artificial neural network (ANN) modeling confirmed the reliability of the experimental results, enabling accurate prediction of surface quality. The findings demonstrate that dry machining of Al-6061 with optimized parameters can achieve a superior surface finish without coolant, enhancing both environmental sustainability and machining efficiency for non-ferrous metals.

Keywords: Surface Roughness (Ra); Dry Machining; Non-Ferrous Metals; Taguchi Method; Sustainable Manufacturing; Cutting Velocity; Orthogonal Array; Dry Milling.

Received on: 28/11/2024, Revised on: 04/02/2025, Accepted on: 27/03/2025, Published on: 07/12/2025

DOI: 10.69888/FTSSM.2025.000575

FMDB Transactions on Sustainable Structures and Materials, 2025 Vol. 1 No. 2, Pages: 91-105

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