Optimization of Process Parameter for Surface Roughness in Milling Process using Response Surface Methodology

Abstract

The aim of this study is to analyze the influence of cutting parameters on surface roughness (Ra) in end milling process. The parameters considered were the spindle speed, feed rate and depth of cut. Response Surface Methodology is utilized to create an efficient analytical model for surface roughness in terms of cutting parameters: feed, cutting speed and depth of cut. In order to model and analyze the effect of each associated factor and minimize the cutting tests, surface roughness models utilizing response surface methodology and the experimental design were carried out in this investigation. The regression model was developed to predict the Surface roughness values from the experimental observations. The regression model and Analysis of Variance (ANOVA) were analyzed using FCC Design of experiments based on Response Surface Methodology. The average surface roughness was considered as the output response. The cutting conditions such as feed rate, spindle speed and depth of cut determine the surface roughness in end milling operation. Surface Roughness generally increases with the increase of speed. The Ra values predicted from the regression model has the good correlation with experimental results.