Manufacturing Technology 2026, 26(3):346-355 | DOI: 10.21062/mft.2026.029

Comparative Surface Roughness Performance of Al7075, Al6061, and Al5052 in End Milling Using Taguchi L16 S/N and Anova

Richard A M Napitupulu ORCID..., Siwan Edi Amanta Perangin-angin ORCID...
Department of Mechanical Engineering, University HKBP Nommensen, Jalan Dr. Sutomo No. 4-A, Medan, Medan, 20235, Nort Sumatra, Indonesia

This study examines the effects of cutting parameters on surface roughness (Ra) for three aluminum alloys AL7075, AL6061, and AL5052 using a Taguchi L16 (4³) design, smaller-is-better signal-to-noise (S/N) analysis, and ANOVA. Experiments were conducted on a 3-axis CNC milling machine with a 2-flute Ø6 mm carbide end mill. Overall, AL7075 produced the smoothest surface (minimum Ra = 0.143 μm), followed by AL6061 and AL5052. The observed trends are consistent with machining mechanics: increasing cutting speed suppresses built-up edge (BUE) and vibration, whereas larger feed and depth of cut (doc) increase chip load and tool deflection. For AL7075, doc and feed were the principal factors (borderline significant in S/N-ANOVA); the mean-optimal setting was S3–F1–D3 = Spindle L3 (N = 2500 rpm), Feed L1 (f = 150 mm.min-1), doc L3 (0.8 mm), while the robust-optimal setting was S4–F1–D3 = Spindle L4 (N = 3500 rpm), Feed L1 (f = 150 mm.min-1), doc L3 (0.8 mm). For AL6061, spindle speed was strongly dominant (≈80.5% contribution; p < 0.001), with S3–F1–D1 = 2500 rpm, 150 mm.min-1, 0.4 mm as the mean optimal and S3–F1–D2 = 2500 rpm, 150 mm.min-1, 0.6 mm as the robust-optimal combination. For AL5052, factor contributions were relatively balanced and not significant at α = 0.05; the mean optimal setting was S4–F2–D3 = 3500 rpm, 250 mm.min-1, 0.8 mm, whereas S/N indicated S1–F4–D4 = 500 rpm, 450 mm.min-1, 1.0 mm (requiring confirmation tests). Across alloys, doc and spindle speed emerged as the most practically influential factors. These results establish ANOVA validated mean and robust (S/N) settings as process guidelines to minimize Ra; confirmation tests are recommended

Keywords: Aluminum alloys, CNC milling, Surface roughness, Taguchi method, Signal-to-noise ratio

Received: January 5, 2026; Revised: May 5, 2026; Accepted: May 7, 2026; Prepublished online: May 11, 2026; Published: June 29, 2026  Show citation

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Napitupulu RAM, Amanta Perangin-Angin SE. Comparative Surface Roughness Performance of Al7075, Al6061, and Al5052 in End Milling Using Taguchi L16 S/N and Anova. Manufacturing Technology. 2026;26(3):346-355. doi: 10.21062/mft.2026.029.
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