Effect of machining parameters on surface roughness in Al 2618 alloy subject to multi-axis machining process using ball nose cutting tools

Recently multi-axis machining technology has improved significantly. It has become a widely accepted method of manufacturing components with complex, free form surfaces. Solid billet materials with negligible internal defects are used in this process. This provides increased durability and fatigue life over equivalent cast components. However, multi-axis machining using ball nose cutting tools leaves cusps as machining marks. The surface quality within the cusps can have a significant influence on the fatigue life and durability of a component. The main objective of this paper is to report the experimental investigation of the effect of different cutting parameters on surface roughness of Al 2618 alloy. This paper reports on an experimental investigation of the effect of different cutting parameters on surface roughness of Al 2618 alloy. A full factorial experimental analysis using four different levels of spindle speed, feed-rate and cutting-tool approach angle was carried out. The results indicate that higher spindle speed, lower feed rate and a cutting tool approach angle of approximately 25° generates a better surface finish.