Flank Wear Prediction Model Development by Response Surface Methodology

Abstract

It is necessary to select the optimum cutting parameters in order to improve the efficiency of any machining process. The selections of the optimum cutting parameters significantly improve the tool life. Hence, in the present investigation, cutting parameters such as cutting speed, feed rate, depth of cut and nose radius were used for flank wear model development for Al-SiC composite. The machining of the composite was carried out using response surface methodology. Face centered composite design with three levels of each factor was used for flank wear study of the developed composite. A response surface model for flank wear was developed in terms of main factors and their significant interactions. The developed model was validated by conducting experiments at different levels of factors used. Furthermore, the model was optimized for minimum flank wear. An error of 3-8% was observed in the modeled and experimental results.