Abstract
For all machining cutting methods, surface roughness is a parameter that greatly affects the working ability and life of machine elements. Cutting force is a parameter that not only affects the quality of the machining surface but also affects the durability of cutter and the level of energy consumed during machining. Besides, material removal rate (MRR) is a parameter that reflects machining productivity. Workpiece surface machining with small surface roughness, small cutting force and large MRR is desirable of most machining methods. Milling is a popular machining method in the machine building industry. This is considered to be one of the most productive machining methods, capable of machining many different types of surfaces. With the development of the cutting tool and machine tool manufacturing industries, this method is increasingly guaranteed with high precision, sometimes used as the final finishing method. Milling using a face milling cutter is more productive than using a cylindrical cutter because there are multiple cutter s involved at the same time. This article presents a study of multi-objective optimization of milling process using a face milling cutter. The experimental material used in this study is X12M steel. Taguchi method has been applied to design an orthogonal experimental matrix with 27 experiments (L27). In which, five parameters have been selected as the input parameters of the experimental process including insert material, tool nose radius, cutting speed, feed rate and cutting depth. The Reference Ideal Method (RIM) is applied to determine the value of input parameters to ensure minimum surface roughness, minimum cutting force and maximum MRR. Influence of the input parameters on output parameters is also discussed in this study
Highlights
Milling is one of the most common machining methods in mechanical machining
The results showed that in order to ensure the purposes of minimum surface roughness, minimum tool wear and ma ximum material removal rate (MRR), it is necessary to work with values of cutting fluid flow rate of 0.5 liter/min, cutting speed of 109.9 m/min, feed rate of 94.2 mm/min and axial depth of cut of 0.9 mm. [20] has optimized the milling process of 465 steel with a TiAlN coating cutting tool: In order to ensure the purposes of minimum surface roughness, minimum cutting temperature and maximum MRR, the suggested cutting speed is 150 m/min, feed rate is 0.1 mm/min, and cutting depth is 0.2 mm
The optimum values of the input parameters are suggested as follow: insert material of TiCN, tool nose radius of 0.3 mm, cutting speed of 125 m/min, feed rate of 500 mm/min and cutting depth of 0.45 mm
Summary
Milling is one of the most common machining methods in mechanical machining This method can be applied on various types of surfaces and materials in the process of machining many different products. With the development of cutting tool technology and machine tools, product quality when machining by milling method using face milling cutters is increasingly improved. In some cases, it is selected as the final machining method. Small surface roughness, small cutting force and large MRR are the objectives to be achieved. Many authors have studied how to determine the value of the processing parameters to ensure small surface roughness, small cutting force and large MRR
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