Statistical analysis of the effect of machining parameters on fatigue life of aerospace grade aluminum alloy (AL 6082T6)

In this research work, aerospace grade aluminium alloy (Al 6082-T6) was analysed for the effect of cutting parameters on the fatigue life of the machined samples and optimization of cutting parameters for response factor. Different combinations of machining parameters were selected according to the ISO 3685 for sample preparation. Fatigue life of the samples was the response variable under investigation. Specimens for the rotating bending fatigue test were prepared according to the BS ISO 1143:2010 standards. The cutting inserts were selected from Sandvik Coromant catalogue recommended for machining of Al 6082-T6 alloy. A Designed of Experiment (DoE) with full factorial design was employed and a total of 81 experiments were performed for combination of cutting parameters. Fatigue life of the samples was observed to decreases with increasing feed rate, which is attributed to the compressive residual stresses at the surface of the samples. However, fatigue life increased with higher cutting speed and Depth of Cut (DoC).