Aluminum alloy 6061-T6 is a commonly used material in various industries, including automotive parts manufacturing. However, its machining process can be challenging due to the occurrence of build-up edge (BUE) at the cutting edges. To address this issue, this research employed trochoidal milling to machine aluminum alloy 6061-T6 specimens, utilizing a small step over and a suitable depth of cut. The engagement of the tool during the machining process generates fluctuating forces, which consequently leads to fluctuations in temperature. This phenomenon is not only observed in trochoidal milling but also in conventional machining methods. The results indicate that the calculated maximum temperature (350°C) is lower than the aluminum's melting point (652°C). Moreover, the experimental results show minimal BUE formation on the cutting edge and an improved milling process.
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