OPTIMIZATION OF FACE MILLING PROCESS PARAMETERS USING RESPONSE SURFACE METHODOLOGY

Abstract

Maintaining good surface quality usually involves additional manufacturing cost or loss of productivity. During the process high cutting frictional forces lead to rise in temperature at workpiece and tool interface which may affect the dimensional and surface quality of the product. Optimum machining parameters can reduce tool wear, to ensure better surface integrity and machining cost. In this paper, the machining parameters i.e. cutting speed (v), depth of cut (d) and feed rate (f) has been optimized for improved surface finish using response surface methodology (RSM). The optimization of the surface roughness (Ra) and tool wear (Tw) has been done  simultaneously by multi response optimization technique and also a mathematical relation between response parameters and input process variables has been developed. The optimized process parameters obtained from machining through RSM were cutting speed of 175.7 m/min, feed rate of 400 mm/min and depth of cut of 0.50 mm, corresponding Tw and Ra were 49.44 µm, 11.38 µm
respectively.