Abstract
This paper presents the optimization of cutting parameters when surface milling according to the stages of the response surface method. The implemented stages of the response surface method include the screening design, initial experiments and response surface design. The objective of the screening design is to select the input parameters for the next experimental stages. The goal of the initial experiments is to check the choice range of the input parameters ensures that the output function is extreme point or not. The aim of response surface design is to build the relationship between output parameters and the input parameters. The machined material in this study is C45 steel, while the used cutting tool is the face mill with PVD-coated inserts. Accordingly, the optimal values of cutting parameters including cutting speed, feed rate and depth of cut are determined at 230 (m/min), 0.23 (mm/toolpath) and 0.888 (mm), respectively. In case of machining with this cutting parameter, the surface roughness of workpiece reaches the smallest value, only about 0.15 µm.
Highlights
The surface roughness of workpieces when machined by machining methods is always a parameter that significantly affects the worktability and life of the workpieces
The results of this study showed that the optimal values of the four above parameters were 7.90, 241.41, 7.98 and 27.76 (m/min), respectively
Equation (1) has a coefficient of determination (R-Square) R2 = 0.9846, very close to 1. This affirms that the surface roughness model has a very good compability with empirical data. This equation is the basis for determination of the value of the cutting parameters to ensure that surface roughness reaches a specific value
Summary
The surface roughness of workpieces when machined by machining methods is always a parameter that significantly affects the worktability and life of the workpieces. The optimum values of cutting velocity, feed rate, and depth of cut that were determined were 60 (m/min), 0.1 (mm/rev), and 0.4 (mm), respectively With these cutting conditions, the optimized value of surface roughness was 2.5μm. They have determined the optimal values of parameters that included the depth of cutting, workpiece speed, number of passes, and grinding wheel speed were 0.5 (mm), 80 (rev/min), 6 (passes), and 1910 (rev/min), respectively In this case, the machined surface roughness had a minimum value of 0.22 μm. The optimum values of cutting speed, feed rate, and depth of cut that were determined in this study had the values of 75 (m/min), 0.06 (mm/tooth), and 0.4 (mm), respectively With these values, the surface roughness had the smallest value of 0.19 μm. The optimization technique used in this study is performed in a sequence of stages of the response surface method
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