Title: Tool geometry and machining variables influence on the surface roughness of end-milling process: a comparative study with application of RSM and GA tools and techniques

Authors: Boppana V. Chowdary; Onella Sookhansingh

Addresses: Mechanical and Manufacturing Engineering, University of the West Indies, St. Augustine Campus, West Indies, Trinidad and Tobago ' Trinidad Inspection Services Limited, Point Lisas Industrial Estate, Couva, Trinidad and Tobago

Abstract: This study investigates the effects of cutting speed, feed rate, depth of cut, and radial rake angle on the surface roughness of aluminium 5083 (Al5083), acrylic and polyethylene terephthalate (PET) in the computer numerical control end-milling operation. Taguchi L9 orthogonal array of experimental design was used to conduct the research. Response surface methodology was employed to generate prediction models. To achieve minimal surface roughness, optimal machining conditions were found using genetic algorithm approach. It was found that the optimal surface roughness for Al5083 was 0.143 µm, acrylic was 0.048 µm and PET was 0.612 µm. Further, it was deduced that the noise factors significantly affected the validation results for Al5083 but had little effect on acrylic and PET. Additionally, the study results confirm that the surface condition of different materials respond differently to identical process parameters and noise conditions.

Keywords: surface roughness; aluminium 5083; acrylic; polyethylene terephthalate; PET; Taguchi experiments; response surface methodology; genetic algorithm; end-milling.

DOI: 10.1504/IJPMB.2024.135749

International Journal of Process Management and Benchmarking, 2024 Vol.16 No.1, pp.1 - 18

Received: 13 Jul 2022
Accepted: 14 Jul 2022
Published online: 04 Jan 2024 *