Comparative Analysis of Aluminium 6061-T6 with Different Stock Leaves Setting on Holes True Position: A Case Study

Abstract

With the evolution of industrial technology, improved machining processes have been developed. With the expansion of machining processes, machining characteristics alter according to the tool and work materials, tools used, machining technique used, etc., increasing surface smoothness, dimensional accuracy, and tool wear. Geometric error is a problem in precision machining due to parameter settings. This research aims to analyse the effect of stock leave setup on achieving precise product hole positions and improving machining process efficiency. The substrate involved was AL6061-T6. This study involved the use of MasterCAM software for simulation analysis to predict the effectiveness of the machining process. Then, the machining process was implemented with different stock leaves of 4 mm and 1 mm using a 5-axis Mazak machine. The result reveals the coordinate measurement machine (CMM) reading is proportional to the stock leave setup. The small reading value of CMM produces better accuracy cutting in machining process. In addition, a small value of stock leave produces a hole position within the specification due to adding additional processes compared to the high value of stock leave. Thus, with suitable parameters, all machining processes can produce a good accuracy of finishing parts and meet customer requirements.