Surface Roughness Prediction in High Speed Flat End Milling of Ti-6Al- 4V and Optimization by Desirability Function of RSM

Abstract

High Speed Machining is applicable for producing parts that require little or no grinding / polishing operations within the required machining tolerances. For achieving required level of quality, selection of cutting tools and parameters in high speed machining is very important. In this study, small diameter flat end milling tool was used to achieve high rpm to facilitate the application of low values of feed and depth of cut to achieve better surface roughness. Machining was performed on a Vertical Machining Centre (VMC) with a high speed milling attachment (HES 510), using cutting speed, depth of cut, and feed as machining variables. Statistical prediction model of average surface roughness was developed using three-level full factorial design of experiments. It was observed that depth of cut is the most dominating factor followed by cutting speed and feed. The developed model was used for optimization by desirability function approach to obtain minimum Ra. Maximum desirability of 95.63% was obtained.