Research Information System
JORDAN JOURNAL OF MECHANICAL AND INDUSTRIAL ENGINEERING, no.19, pp.91-104, 2025 (ESCI)
Aluminum alloys are widely used in various industries due to their high mechanical properties and low specific gravity. However, inappropriate cutting parameters can lead to built-up edge (BUE) formation, degrading the workpiece's surface quality and reducing tool life. This study investigates the effects of conventional and trochoidal milling methods on response variables, including surface roughness (Ra), circularity, and cutting forces (Fr), for AA 7075-T6 aluminum alloy. Experimental work was carried out using two cutting methods (trochoidal and conventional), three cutting speeds (175, 225, and 275 m/min), and three feed rates (0.09, 0.12, and 0.15 mm/tooth). The Taguchi method and Grey Relational Analysis (GRA) were used for multi-response optimization, and Analysis of Variance (ANOVA) was used to assess the effect of control factors on machining performance. The results indicate that cutting methods influence the performance of the response variables. Feed rate influenced surface roughness (Ra) by 57.28%, while the milling method influenced circularity and cutting forces by 73.73% and 68.97%, respectively. In addition, the trochoidal milling method exhibited a stable cutting force profile with fewer harmonic components than the conventional method. This stability and the shorter cycle time achieved by trochoidal milling highlight its efficiency advantages. These results suggest that the trochoidal method offers potential applications and efficiency benefits in precision-demanding industries such as automotive and aerospace.