Machining involves the thermal, elastic and plastic deformations of the surface layer which result in strain hardening, structural changes and development of residual stresses. These cause surface irregularities which may increase the risk of fatigue failure of material during usage. This study involves the investigation of the influence of cutting speed, feed rate and tool geometry on the fatigue life of end-milled specimens of 2024-aluminium alloy using a design of experiment approach. The experimental design constructed was such that the specimens were subjected to different machining conditions. Data analysis was carried out with Relia Soft Office TM 7 DOE++ software and Analysis of Variance (ANOVA). The study showed that by decreasing the feed rate (from 60mm/min to 7mm/min) and increasing the cutting speed (from 3.77m/min to 48.25m/min) significantly resulted in a higher fatigue life (from 1.93x10 3 cycles to 2.53x10 3 cycles). Whereas, the rake angle had the least significant effect on the fatigue life, it was discovered that the feed rate was found to be the most influential factor.
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