Optimization of Milling Parameters for Burr Suppression in Aluminum Alloys Using Taguchi Method

This study optimizes milling parameters to suppress burr formation in aluminum alloys (5A06, 6061, 6063) using Taguchi L9 orthogonal experiments and ANOVA. Cutting speed (1000-5000 r/min), feed rate (0.01-0.1 mm/r), and depth of cut (1-5 mm) were evaluated for exit-side (B1) and side-direction (B2) burr dimensions. Signal-to-noise ratio analysis identified optimal parameters: 5000 r/min speed, 0.055 mm/r feed, 1 mm depth for 5A06/6061, and 5000 r/min, 0.01 mm/r feed, 1 mm depth for 6063. Parameter influence hierarchies revealed feed rate dominant for 5A06/6061, while cutting speed most critical for 6063, with depth of cut least impactful across all alloys. ANOVA statistically validated these trends, confirming alloy-specific control mechanisms. Validation achieved up to 90% burr reduction, providing a practical framework to eliminate deburring in aluminum milling processes.