Modeling and Optimization of Process Parameters for Surface roughness and Cutting Forces on End Milling using RSM and Taguchi Method

Abstract

End milling is one of the most used machining techniques for removing metal from objects and milled surfaces. It is widely used in tools, aerospace, automotive, machine design, and production for joining other parts. Surface roughness is a crucial indicator of a product's technological excellence and a component that significantly affects manufacturing costs. The effects of several factors of the milling process, such as rotational speed, cutting speed, depth of cut, number of cutting edges and feed rate, find their influence on the surface finish. Surface roughness, cutting forces, and material removal rate were chosen as process responses. Taguchi method and the RSM in the evaluation and optimization of the machining parameters of end milling for the machining of Al 6063/SiO 2 by using Minitab 19. The vertical milling machine was used to perform experiments based on the Taguchi L 27 orthogonal array. The rotational speed, cutting speed, weight percentages of Nano SiO 2 (1, 3 and 5), number of cutting edges, feed rate, and depth of cut were considered machining parameters. According to ANOVA results, additions and cutting speed are the factors that have the greatest impact on the model metal removal rate.