Abstract
Optimization of cutting parameters in micro-milling is an important measure to improve surface quality and machining efficiency of the workpiece. Investigation of micro-milling forces prediction plays a positive role in improving machining capacity. To predict micro-milling forces and optimize micro-milling cutting parameters (per-feed tooth (fz), axial cutting depth (ap), spindle speed (n) and tool extended length (l)), a rotatable center composite experiment of micro-milling straight micro-groove in the workpiece of Al7075-T6 were designed, based on second-order response surface methods. According to the experiment results, the least square method was used to estimate the regression coefficient corresponding to the cutting parameters. Simultaneously, the response prediction model of micro-milling was established and successfully coincide the predicted values with the experiment values. The significance of the regression equation was tested by analysis of variance, and the influence of micro-milling cutting parameters on force and top burrs morphology was studied. The experiment results show that in a specific range of cutting parameters, ap and fz have a significant linear relation with the micro-milling force and the top burrs width. According to the optimal response value, the optimized cutting parameters for micro-milling obtained as: n is 11,393 r/min, fz is 6 µm/z, ap is 11 μm and l is 20.8 mm. The research results provide a useful reference for the selection of cutting parameters for micro-milling.
Highlights
Because micro-milling has a wide range of applications in the aerospace, biomedical, electronics, automotive and other related fields, the cutting mechanism and performance have been extensively studied to improve the quality of the machined surface [1]
The rotatable center composite experiment was selected, and the quadratic response surface model was analyzed by variance and combined to obtain the response surface graph, which intuitively analyses the relationship between the cutting parameters and the response
Response surface method is adopted to study the mathematical relationship between the response and the independent variables
Summary
Because micro-milling has a wide range of applications in the aerospace, biomedical, electronics, automotive and other related fields, the cutting mechanism and performance have been extensively studied to improve the quality of the machined surface [1]. The rotatable center composite experiment was selected, and the quadratic response surface model was analyzed by variance and combined to obtain the response surface graph, which intuitively analyses the relationship between the cutting parameters and the response (micro-milling force and top burrs width).
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