Abstract
Tool vibration and surface roughness are two important parameters which affect the quality of the component and tool life which indirectly affect the component cost. In this paper, the effect of cutting parameters on tool vibration, and surface roughness has been investigated during end milling of EN-31 tool steel. Response surface methodology (RSM) has been used to develop mathematical model for predicting surface finish, tool vibration and tool wear with different combinations of cutting parameters. The experimental results show that feed rate is the most dominating parameter affecting surface finish, whereas cutting speed is the major factor effecting tool vibration. The results of mathematical model are in agreement with experimental investigations done to validate the mathematical model.
Highlights
Due to its capability for enhancing product rate coupled with desired product quality, high-speed machining has gained popularity in manufacturing industry
Mathematical models were developed to predict the surface roughness, acceleration vibration amplitude, and tool wear by relating them with process parameters such as cutting speed, axial feed rate, and depth of cut
At lower depth of cut, that is, d.o.c at 0.75, we find lower tool life and tool vibration with better surface finish
Summary
Due to its capability for enhancing product rate coupled with desired product quality, high-speed machining has gained popularity in manufacturing industry. Higher values of cutting parameters used in high-speed machining adversely affect the surface roughness of workpiece and tool vibration. Empirical models can correlate surface finish, tool vibration, and tool wear to the machining parameters for machining of EN-31 die steel machining with tungsten carbide tool in high-speed machining. Hamdan et al [2] investigated the machining parameters like speed, feed, and axial depth of cut with dry and wet machining in high-speed machining of stainless steel using coated carbide tool for better surface finish. Raju et al [8] reported an integrated study of surface roughness and cutting parameters in end milling of 6061 aluminum alloy with HSS and carbide tools under dry and wet conditions. Prajina [9] focused on RSM for the multiple response optimizations in CNC end milling operation to get maximum material removal rate, minimum surface roughness, and less force. Chen [13] studied the cutting force and surface finish during machining of medium hardened steel (45–55 HRC) using CBN tool and concluded that thrust force was the largest among the three cutting force components
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