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Effect of High-Speed Dry Face Milling on Surface Integrity Characteristics of AZ91 Mg Alloy

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Abstract

In the present study, high-speed dry face milling is performed on AZ91 magnesium alloy using uncoated carbide inserts. The most influential surface integrity characteristics, such as surface roughness, hardness, microstructure and residual stresses, are investigated for a set of milling parameters chosen from the Taguchi design of experiments. The impact of machining conditions, such as feed rate, cutting speed and depth of cut on the surface integrity characteristics, are identified in order to improve the overall functionality of the alloy. Grey Relational Analysis optimization method is implemented to identify the optimal milling conditions. The results showed that high-speed dry face milling is very influential in improving the overall surface integrity characteristics of this alloy.

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Acknowledgements

The authors thank the Aeronautics R & D Board, DRDO, New Delhi for the funding support. Sanction Code: MSRB/TM/ARDB/GIA/19-20/044.

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Authors and Affiliations

  1. Department of Mechanical Engineering, NMAM Institute of Technology, Udupi, Nitte-574110, India

    Vikas Marakini, Srinivasa P Pai & Bhaskara P Achar

  2. Department of Metallurgical and Materials Engineering, NITK, Mangalore, Surathkal-575 025, India

    Udaya K Bhat

  3. Department of Mechanical Engineering, DIAT, Pune, 411 025, India

    Dinesh Singh Thakur

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  1. Vikas Marakini
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Correspondence to Srinivasa P Pai.

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This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Magnesium. The issue was organized by Prof. C. (Ravi) Ravindran, Dr. Raja Roy, Mr. Payam Emadi, and Mr. Bernoulli Andilab, Ryerson University.

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Marakini, V., Pai, S.P., Bhat, U.K. et al. Effect of High-Speed Dry Face Milling on Surface Integrity Characteristics of AZ91 Mg Alloy. J. of Materi Eng and Perform 32, 2749–2757 (2023). https://doi.org/10.1007/s11665-022-07187-4

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