1 Research Method

1.1 Design Framework

The process pathway was structured to ensure full reproducibility. Al6061 blocks were machined using a 3‑axis CNC mill with fixed toolpaths, controlled spindle speeds, and uniform coolant conditions. The design emphasized constant cutting forces to eliminate tool‑wear variability.

1.2 Data Sources

Data included surface roughness profiles, anodizing‑layer thickness measurements, dimensional shifts before and after treatment, and reflectivity values. Measurement datasets were collected across five repeated trials per parameter group.

1.3 Experimental Tools and Models

1.3.1 Machining Setup

A standardized 10 mm end mill, 8000 rpm spindle speed, and 600 mm/min feed rate were used. Calibration blocks verified machine repeatability.

1.3.2 Surface‑Preparation Instruments

Glass‑bead media (80–120 mesh) and a 0.5–0.7 MPa pressure range were applied. Surface roughness testers and an optical microscope validated Ra and pattern distribution.

1.3.3 Anodizing System

Type II sulfuric‑acid anodizing was conducted at 20 °C with fixed current density. Coating thickness was measured via eddy‑current probes.

2 Results and Analysis

2.1 Surface Roughness Changes

Table 1 summarizes mean Ra before and after sandblasting.

Table 1 Surface Roughness (Ra) Changes

The increase in Ra aligns with existing data on bead‑blast texturing, confirming consistent matte‑finish generation.

2.2 Coating Thickness and Dimensional Impact

Figure 1 illustrates average anodizing thickness across samples.

Figure 1 Anodizing Coating Thickness Distribution

Mean thickness stabilized at 12.4 µm. Dimensional measurements demonstrated an outward growth ratio matching standard anodizing expansion models.

2.3 Comparison With Existing Research

Results show similar roughness shifts reported in machining‑surface studies, while coating uniformity presents lower variance due to controlled pre‑anodizing texture. The process combination reduces color blotching often observed in untreated surfaces.

3 Discussion

3.1 Interpretation of Results

The correlation between media size and Ra confirmed expected abrasive‑impact behavior. Uniform anodizing was aided by consistent surface energy introduced through sandblasting.

3.2 Limitations

Data were limited by fixed equipment configurations and a single alloy temper. Additional testing across broader machining parameters could refine generalization.

3.3 Practical Implications

Manufacturers requiring both cosmetic finishes and precision can apply this standardized route to reduce rework and surface‑defect rates. Data support its suitability for robotics housings, consumer electronics enclosures, and lightweight structural components.

Controlled sandblasting combined with Type II anodizing reliably produces uniform textures and coatings on CNC‑milled Al6061 components. Dimensional stability remains within standard tolerance limits, and surface properties meet requirements for functional and decorative applications. Future work may explore automated media‑distribution control and comparative studies with hard‑anodizing.

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