Capability Analysis of AZ91D Magnesium Alloy Precision Milling Process with Coated Tools
Jarosław Korpysa1, Józef Kuczmaszewski1, Ireneusz Zagórski1
1Department of Production Engineering, Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, Poland.
Materials (Basel, Switzerland)
|April 28, 2023
Summary
This study determined process capability indices for AZ91D magnesium alloy precision milling. Optimizing machining conditions and tool coatings significantly improved dimensional accuracy, achieving tighter tolerances.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Statistical Quality Control
Background:
- Process capability analysis is crucial for monitoring product compliance in manufacturing.
- AZ91D magnesium alloy presents unique challenges in precision machining due to its properties.
- Tool coatings play a vital role in enhancing machining performance and surface integrity.
Purpose of the Study:
- To determine the process capability indices (Pp and Ppk) for the precision milling of AZ91D magnesium alloy.
- To evaluate the impact of variable technological parameters and protective coatings (TiAlN and TiB2) on machining outcomes.
- To establish optimal machining conditions for achieving high dimensional accuracy.
Main Methods:
- Precision milling of AZ91D magnesium alloy components using end mills with TiAlN and TiB2 coatings.
- Measurement of dimensional accuracy of machined components using a machining center with a workpiece touch probe.
- Calculation of process capability indices (Pp and Ppk) based on dimensional measurements.
Main Results:
- The type of tool coating and machining conditions significantly influenced the machining effect and dimensional accuracy.
- Optimized machining conditions, particularly cutting speed and feed per tooth, enabled achieving a capability level with a 12 µm tolerance.
- Unfavorable conditions resulted in significantly wider tolerances, up to 120 µm, highlighting the importance of parameter selection.
Conclusions:
- Appropriate selection of machining conditions and tool coatings is essential for achieving high process capability in AZ91D magnesium alloy milling.
- Adjusting cutting speed and feed per tooth are key factors for improving process capability.
- Incorrect selection of capability indices can lead to an overestimation of the actual process capability, emphasizing the need for careful index selection.
