Analysis of Al-Li Alloy Machinability Characteristics for Better Surface Smoothness using the Taguchi Method

Abstract

Al-Li alloys are 20% lighter than conventional high-strength aluminium alloys and have higher standards for wear and damage tolerance. However, while possessing a low density, they have excellent yield and strengths. When it comes to use in aerospace and defense applications, it will soon displace other materials as the favoured material. The focus of the current research is on the optimal parameters that influence surface hardness and roughness in a variety of machining operation settings. Al-Li alloy 2099 (94.309 of Al & 5.691% Li alloy) was machined using Sol XL coolant (1:20 water based) and the following settings: speed range 3000-6000 rpm, feed rate 150-450 mm/min, depth of cut 0.1-0.2 mm. The Taguchi method with the Signal-to-Noise (S/N) ratio for process optimization. was used to record data for the milling of Al-Li alloy with variable factors on a Hartford Omins VMC 1270 CNC machine utilising a 16mm flat Widia ALUFLASH series 3AN9 solid carbide tool. According to the Taguchi method, the cutting parameters of RPM (4000 rev/min), feed rate (300 mm/min), depth of cut (0.15 mm), and coolant gave the best surface smoothness and hardness. Therefore, in order to reduce the expense and duration of the experiment, the optimal setting levels of the process parameters reported in this work might be applied to the machining of Al-Li work pieces that are utilised in aircraft and aerospace components.