Experimental studies and optimization of process parameters in face milling using response surface method

Abstract

This thesis investigates the cutting forces and surface roughness in the face milling operation on Al6063 using a carbide tool. The effects of cutting parameters (cutting speed, feed rate, and depth of cut) on cutting forces and surface roughness are examined. The experiments are conducted on a horizontal milling machine with a carbide side and face milling cutter. Unlike traditional choices such as HSS tools or PCD tools, carbide, which are primarily designed for machining metals and alloys, are utilized in this study. In this experiment force measurement is done by Kistler tool dynamometer and surface roughness is measured by measured using a stylus-type profilometer called Talysurf. The results show that increasing cutting speed initially leads to an increase in cutting forces, but after a certain point, the forces start to decrease due to reduced tool workpiece interaction and workpiece softening caused by elevated temperatures. Higher feed rates and depth of cut result in increased cutting forces. Regarding surface roughness, an increase in cutting speed generally results in decreased roughness, indicating a smoother surface finish. However, an increase in feed rate and depth of cut shows an inverse relationship with surface roughness, leading to increased roughness values. The findings emphasize the importance of selecting appropriate cutting parameters to optimize cutting forces and surface roughness in face milling of Al6063. The use of carbide tools provides insights into their performance in machining AL6063. Future research can explore advanced tool materials or coatings to further improve the machining process and surface quality of Al6063.