Modelling and application of response surface optimization to optimize cutting parameters for minimizing cutting forces and surface roughness in high-speed, ball-end milling of Al2014-T6

Abstract

In this research study, empirical mathematical models for cutting forces and surface roughness have been developed to investigate the effect of axial depth of cut, feed, radial depth of cut and cutting speed in high-speed ball-end milling of Al2014-T6. Ball-end milling experiments have been planned using central composite design based on response surface methodology. The mathematical models have been established and tested for adequacy. A full quadratic model has been adopted for modelling. It has been found that axial depth of cut is the most dominant cutting parameter for the tangential and axial cutting forces, accounting for 49.38 and 47.12% contributions, respectively. Radial depth of cut is the most dominant parameter for radial force and contributes 69.94% for it. Results also revealed that force components decrease with increase in cutting speed. There is very small variation in cutting force components in the cutting speed range of 75–150 m/min at lower values of axial and radial depth of cut. Surface roughness is effected by cutting speed largely followed by feed. Multi-objective optimization has been performed using composite desirability to optimize the cutting parameters for minimum surface roughness and cutting forces simultaneously. Confirmation tests have been conducted using optimal set of cutting parameters. The results of confirmation tests are very close to the predicted results.