Experimental Investigation of the Effect of Tool Rotational Speed and Initial Workpiece Temperature in Dry Milling on Energy Consumption, Hardness Variation, and Corrosion Rate of AA6061 Aluminum Alloy

Pourhoseini, S.H.; Tymouri, M.J.; Sedehi, Sayyed Mohammadreza; Vakili-Azghandi, Mojtaba; Baghban, M.

doi:10.30501/acp.2026.582016.1196

Experimental Investigation of the Effect of Tool Rotational Speed and Initial Workpiece Temperature in Dry Milling on Energy Consumption, Hardness Variation, and Corrosion Rate of AA6061 Aluminum Alloy

Document Type : Original Research Article

Authors

S.H. Pourhoseini ¹

M.J. Tymouri ²

Sayyed Mohammadreza Sedehi ³^{, 4}

Mojtaba Vakili-Azghandi ⁵

M. Baghban ⁶

¹ Associate Professor, Department of Mechanical Engineering, Faculty of Engineering, University of Gonabad, Gonabad, Iran.

² BSc Student, Department of Mechanical Engineering, Faculty of Engineering, University of Gonabad, Gonabad, Iran.

³ PhD Student, School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran.

⁴ Chief Executive Officer (CEO), Farham Rad Mehr Co., Gonabad, Iran.

⁵ Assistant Professor, Department of Materials Engineering, Faculty of Engineering, University of Gonabad, Gonabad, Iran.

⁶ Assistant Professor, Department of Mechanical Engineering, Faculty of Engineering, University of Gonabad, Gonabad, Iran.

10.30501/acp.2026.582016.1196

Abstract

This study experimentally investigated the effects of tool rotational speed and initial workpiece temperature on energy consumption, surface hardness, and corrosion behavior of AA6061 aluminum alloy during milling. The results showed that energy consumption exhibited a nonlinear trend, initially decreasing and then increasing with increasing tool rotational speed and initial workpiece temperature, with minimum and maximum values of approximately 100–120 J and 170–190 J, respectively. Increasing energy input generally enhanced surface hardness up to an optimum level, whereas severe thermomechanical loading caused a slight reduction in hardness. XRD analysis also revealed a reduction in crystallite size and an increase in lattice strain under higher energy conditions. Overall, the controlled adjustment of machining parameters and energy consumption can effectively optimize surface hardness and microstructural evolution in AA6061.

Keywords

Milling

Aluminum

Corrosion

Hardness

Temperature

Tool Rotational Speed

Subjects

Wear Resistance

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