Abstract
This article presents empirical study results when milling SCM440 steel. The cutting insert to be used was a TiN coated cutting insert with tool tip radius of 0.5 mm. Experimental process was carried out with 18 experiments according to Box-Behnken matrix, in which cutting speed, feed rate and cutting depth were selected as the input parameters of each experiment. In addition, cutting force was selected as the output parameter. Analysis of experimental results has determined the influence of the input parameters as well as the interaction between them on the output parameters. From the experimental results, a regression model showing the relationship between cutting force and input parameters was built. Box-Cox and Johnson data transformations were applied to construct two other models of cutting force. These three regression models were used to predict cutting force and compare with experimental results. Using parameters including coefficient of determination (R-Sq), adjusted coefficient of determination (R-Sq(adj)) and percentage mean absolute error (% MAE) between the results predicted by the models and the experimental results are the criteria to compare the accuracy of the cutting force models. The results have determined that the two models using two data transformations have higher accuracy than model not using two data transformations. A comparison of the model using the Box-Cox transformation and the model using the Johnson transformation was made with a t-test. The results confirmed that these two models have equal accuracy. Finally, the development direction for the next study is mentioned in this article
Highlights
Milling method is widely used in mechanical machining by its high machining productivity.Thanks to the advancement of cutting tool making technology as well as the experimental equipment, the precision of the milling method is improved
With the expectation that the cutting force during milling process is of small value, many studies have been done to build the cutting force model
Study on building cutting force model by theoretical method has been done by many authors, such as: when using face milling cutter [1, 2], when using ball end milling [3,4,5], when using cylindrical end mill [6]
Summary
Milling method is widely used in mechanical machining by its high machining productivity.Thanks to the advancement of cutting tool making technology as well as the experimental equipment, the precision of the milling method is improved. With the expectation that the cutting force during milling process is of small value, many studies have been done to build the cutting force model. When building cutting force models according to these studies, the number of calculations is very large, and there is still a need for more experimental studies to determine some parameters, such as coefficient of friction and shear force coefficient. This method is time consuming and costly
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