Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

The automotive industry is looking to adopt environmentally-friendly machining processes for automotive components. This study intends to investigate the machining parameters affecting the machinability of hypereutectic Al-Si alloys in the context of surface roughness and tool life via a DLC coated face milling cutter inserted under dry cutting conditions. The machining parameters used in this study were cutting speeds of 250 m/min and 350 m/min, feed rates of 0.02 mm/tooth and 0.04 mm/tooth, and a constant depth of cut of 0.3 mm. The orthogonal full factorial (2³) method was used for the experimental trials. A commercial software called Minitab 17 was used to generate the analysis of variance (ANOVA) and the mathematical prediction model for each machining response. The experimental results confirmed that an excellent surface finish was achieved with a value of as low as 0.140 µm, while the highest value for tool life of 105.47 minutes was realized with face milled aluminium alloy A390. From the analyses, it was confirmed that the feed rate is the most significant machining factor affecting surface roughness, while in the case of tool life; cutting speed is the most influential machining factor. The main effect plot showed that the optimum cutting condition for realizing low surface roughness and longer tool life is at 250 m/min, a feed rate of 0.02 mm/tooth, and radial depth of cut 12.5 mm. The prediction model for surface roughness and tool life was developed and reported low percentage errors.

Machining is one of the most important processes in producing automotive component such as difficult-to-cut FCD700 cast iron grade. Efforts are continuously made to improve the machining technique for the benefit of human and environment. This paper presents an environmental friendly when turning FCD700 cast iron using carbide tool in the absent of coolant. The turning process was carried out in three medium of dry conditions i.e. without air, chilled air and normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Result shows that the average surface roughness (Ra) was greatly affected by the feed rate and the effect of depth of cut was negligible. Low Ra value was produced when using high cutting speed, especially at medium air temperature of 10 deg C. Whereas when turning at high depth of cut and high feed rate, the tool life was shorten drastically. In addition, the cutting speed was significantly affecting the tool life. The tool life was found to be inversely proportional with the cutting speed. The longest tool life was obtained at cutting speed of 100 m/min, feed rate of 0.15 mm/rev, depth of cut of 0.2 mm and temperature of -2 deg C. Generally, chilled air at temperature of -2deg C will increase the tool life, but the Ra obtained was deteriorated when compared at higher temperature of chilled air and without air cutting environment. Therefore, these findings can be used a guide depending on the preference of the user, either to obtain a better tool life or Ra value.

Aloi aluminum menjadi tumpuan dalam aplikasi komponen automotif disebabkan sifatnya yang ringan yang dapat membantu mengurangkan penggunaan bahan api. Umum mengetahui bahawa komponen ringan yang diperbuat daripada tuangan aloi aluminium lebih kos efektif berbanding penggunaan tuangan besi untuk blok enjin, dan piston. Antara aloi aluminium yang mendapat perhatian pengkaji adalah berasaskan aloi Al-Si seperti aloi penuangan acuan dengan 9.5 wt.% Si (383), aloi penuangan pasir dengan 18.5 wt.% Si (A390) dan semburan aloi dibentuk dengan 25 wt.% Si (Al-25Si). Aloi A390 adalah sesuai untuk menggantikan komponen tuangan besi kerana kandungan silikon yang tinggi ini dapat mengurangkan pengembangan haba, dan ciri-ciri kakisan yang baik. Artikel ini membentangkan pemerhatian yang dilakukan terhadap mikrostruktur aloi aluminum A390 di bawah permukaan yang telah dimesin kisar. Parameter pemotongan yang dikaji ialah laju pemotongan 250-350 m/min, kadar suapan 0.02-0.04 mm/gigi, dan lebar radius 12.5 mm-25 mm. Manakala kedalaman paksi dimalarkan pada 0.3 mm. Pemesinan kisar dilakukan dalam keadaan kering dan kriogenik. Pemerhatian terhadap mikrostruktur mendapati terdapat kesan pemanasan pada laju pemotongan 350 m/min, kadar suapan 0.02 mm/gigi, lebar jejari 12.5 mm dalam keadaan pemotongan kering dengan mata alat yang telah haus. Manakala untuk parameter pemotongan yang lain tiada kesan pemanasan diperhatikan. Tiada sebarang perubahan mikrostruktur diperhatikan bagi julat parameter pemotongan yang dikaji. Ini menunjukkan, suhu pemotongan yang terjana adalah rendah dan tidak menyebabkan sebarang perubahan mikrostruktur bagi julat pemotongan kajian.

Magnesium alloy is one of the lightest materials with a high strength to weight ratio and excellent machinability, which makes it attractive and suitable for various industrial applications such as automotive and aerospace components. For these particular industrial components, the end products require a mirror-like finish. This article details a statistical analysis about the effect of milling parameters on the surface roughness of Magnesium alloy AZ91D in the dry milling process. The historical data approach in the response surface methodology (RSM) was utilized to determine the cause and effect relationship between the input variables and output response. The effect of milling parameter studied was cutting speed (900 – 1400 m/min), feed rate (0.03 - 0.09 mm/tooth), and radial depth of cut (0.2 - 0.3 mm). The results confirmed that the interaction between feed rate and cutting speed is the primary factor controlling the surface evolution. The responses of various factors were plotted using a two-dimensional interaction graph and the cubic empirical model was developed at 95% confidence level. The optimum condition for achieving the minimum surface roughness was a cutting speed of 977 m/min, a feed rate of 0.02 mm/tooth, and an axial depth of cut of 0.29 mm. With this optimum condition, a surface arithmetic roughness of 0.054 μm is expected. This study confirmed that by milling AZ91D at high speed cutting, it is possible to eliminate the polishing process to achieve a super mirror-like finishing.