Analysis of Cutting Forces and Optimization of Cutting Parameters in High Speed Ball-end Milling Using Response Surface Methodology and Genetic Algorithm

Abstract

The stability of the machine tool mainly depend on the cutting force in machining process. In the present study, the influence of cutting speed, feed per tooth, axial depth of cut and radial depth of cut during high speed ball-end milling of Al2014-T6 under dry condition has been studied. Response surface methodology was used for generating the experimental plan for conducting the experiment. The cutting force components i.e. tangential and radial forces were measured and then analysis of variance (ANOVA) was performed. It has been found that the quadratic model is best fitted for prediction of the force components. The analysis of result shows that the cutting forces increases as increase in feed per tooth and axial depth of cut but decreases with increase in cutting speed. Radial depth of cut has significant effect on the cutting force components. The optimization of cutting force components was done by coupling response surface methodology and genetic algorithm. The optimization process was performed in MATLB.