Influence of Lubrication on Vibration Response and Surface Roughness in Milling of Aluminum 6061

Abstract

Aluminum is used widely for components of renewable energy, such as wind and hydro turbines. Some of these components require a milling process to improve surface quality. This research presented the influence of lubrication on vibration and surface roughness in the milling process. The first step, the modal parameters data were obtained by the impulse response method using a hammering test with an impulse hammer, then the milling tests experiment were conducted in three different cutting conditions i.e. dry cutting, wet cutting with coolant and oil. The three-axis accelerometer was used to collect acceleration signals of milling test. The collected acceleration signals then were analyzed using Fast Fourier Transform (FFT) to first transform the signals into frequency domain and after that more phenomenon of the milling process in frequency domain were analyzed. Then, the surface roughness was measured using a surface roughness tester. The results showed that the amplitude of signal is lower in milling with lubricant than dry cutting. The cutting condition was stable in wet cutting for both types of lubricant while the chatter occurs in dry cutting. Then, the surface roughness for wet cutting is better than dry cutting and the best of roughness is wet cutting with lubricant of coolant in this experiment.