Abstract
This paper is focused on the multi criteria optimization of precision ball end milling process of hardened 55NiCrMoV6 steel. The proposed method enables the selection of optimal input parameters which affect the minimization of cutting forces and vibrations signals, as well as the maximization of process efficiency. The experiment includes the measurement of forces and vibrations during the milling tests with variable input parameters. Ultimately, the optimization of the ball end milling process with the application of response surface method is carried out.
Highlights
Ball end milling of molds and dies made of hardened alloy steels is very often conducted as a finish process, which imposes restrictive requirements on machined surface’s quality and tool’s condition
The surface roughness of the machined surfaces can be affected by the kinematic-geometric parameters, frictional effects in the tool-work material inter-face [1], process stability [2], plastic-elastic deformations of work material induced by the ploughing mechanism [3, 4], as well as the thermal phenomena in the cutting zone [5,6,7]
The application of these optimal cutting parameters gave cutting forces lower than 170 N, acceleration of vibrations lower than 55 m/s2 and material removal rate higher than 3820 mm3/min
Summary
Ball end milling of molds and dies made of hardened alloy steels is very often conducted as a finish process, which imposes restrictive requirements on machined surface’s quality and tool’s condition. The vibrations are mainly induced by the cutting forces and milling process kinematics, and they are sensitive to the selected machining parameters and tool’s slenderness [9]. Coating materials, combined with different tool radiuses to obtain the minimum surface roughness values during end milling process of AISI H13 hot work steel in dry cutting conditions. Masmiati et al [18] applied the response surface method (RSM) to the optimization of surface integrity after ball end milling of S50C steel. This study is focused on the optimal selection of surface inclination angle α and feed per tooth fz, in order to minimize the forces and vibrations generated during ball end milling and maximize the process efficiency. The proposed optimization procedure is carried out with the application of response surface method
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