Title: Multi-response optimisation of hard milling process parameters based on integrated Box-Behnken design with desirability function approach

Authors: A. Tamilarasan; K. Marimuthu

Addresses: Department of Mechanical Engineering, Coimbatore Institute of Technology, Civil Aerodrome Post, Coimbatore, 641 014, Tamilnadu, India ' Department of Mechanical Engineering, Coimbatore Institute of Technology, Civil Aerodrome Post, Coimbatore, 641 014, Tamilnadu, India

Abstract: The mathematical modelling and multi-response optimisation of cutting forces, work piece surface temperature and sound pressure level during hard milling of 100MnCrW4 tool steel using coated (TiN+TiAlN) carbide inserts were presented in this paper based on integrated Box-Behnken design with desirability function. The parameters that influence hard milling such as work material hardness, nose radius, feed per tooth, radial and axial depth of cut were discussed. Various test results and reliability of developed quadratic models were verified using analysis of variance (ANOVA) and they were found to be highly close to experiment and significant. The optimised results were validated experimentally and less than 2% error variation was found. Work material hardness, feed per tooth and nose radius have a significant influence on all response variables. Abrasion marks, coating peel off on the tool surface and saw tooth chips were characterised through SEM analysis.

Keywords: hard milling; Box-Behnken design; BBD; work material hardness; nose radius; workpiece surface temperature; WST; sound pressure level; SPL; cutting force; multi-response optimisation; desirability function; mathematical modelling; tool steel; coated carbide inserts; depth of cut; analysis of variance; ANOVA.

DOI: 10.1504/IJMMM.2014.060555

International Journal of Machining and Machinability of Materials, 2014 Vol.15 No.3/4, pp.300 - 320

Received: 05 Oct 2013
Accepted: 06 Dec 2013
Published online: 13 May 2014 *

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