Optimisation of Machining Parameters for CNC Milling of Magnesium Alloy AZ91 by Using the Taguchi Technique

Abstract

The suggested research will focus on finding the best combination of machining settings of Magnesium Alloy (AZ91) using Taguchi's method. Throughout the machining procedure, a multitude of variables impact the quality of the final product. Surface imperfection significantly affects the quality of machined Mg Alloy (AZ91) components. The roughness of the surface (R_a) can be controlled by altering the machining settings, manufacturers have the opportunity to save manufacturing costs without compromising product quality. By minimising waste, enhancing tool life, and lowering the requirement for post-processing activities, optimising dimensions in order to machine the ideal roughness on the surface can help minimise the cost of production. For each such changeable process parameter, the parameters were set at three different levels of research to optimise the process. A carbide end mill was used for machining on a CNC milling machine. Taguchi's approach was used to construct an experiment design (L9 orthogonal array) for the experiments. Using an ANOVA, the significance of each parameter's influence was determined. For optimal AZ91 surface quality, the recommended control factor parameters are 0.22 m, 3000 rpm spindle/speed of cutting, 0.5 mm depth of cut, and 150 mm/min input rate. Surface irregularity was also influenced by the supply rate and the depth of cut, albeit to a smaller amount than by the cutting speed. We used regression analysis and response surface methods to learn more about the relationship between process variables and product characteristics.