Machining parameters and distortion analyses in end milling of AA2050 and AA7050

In this study; feed rate, spindle speed, and radial depth of cut which directly affect the machining distortion, were studied by the usage of tap test and the Box-Behnken experimental design method for AA2050 and AA7050. Based on the optimum cutting parameters obtained from the experimental design studies, materials were machined in a milling center with using a carbide end mill. Depending on the optimum parameters, cutting speed, material removal rate, and spending time were calculated for mass production terminology. Also, with the optimum parameters, on the machined parts; geometric dimensioning and tolerance data such as perpendicularity, parallelism and flatness were examined, the distortion values of the workpiece were obtained. The obtaining results were tested to be usable in the aerospace industry, with geometric distortion values such as perpendicularity, parallelism, and flatness. With the optimum cutting parameters obtained, more distortion was observed in AA2050 more than AA7050. Based on the distortion analysis, improvements have been observed on the workpieces by using optimum cutting parameters which are compared with generally using cutting parameters.