Mathematical Modelling of Surface Roughness Through Machining Parameters and Machining Time During the Dry Milling Process

Abstract

This paper investigates the effects of milling parameters on the surface roughness and surface texture by applying RSM. The most important measures of surface quality during the machining process is the average surface roughness (Ra), and it is mostly caused by many machining parameters, such as true rake angle and side cutting edge angle, cutting speed, feed rate, depth of cut, nose radius, machining time etc. In this work, an experimental investigation through mathematical modelling was carried out to study the effect of cutting parameters such as; cutting speed, feed rate and machining time on surface roughness during the dry end milling process of cold rolled steel C62D. The experiment is executed on the basis of a three level factorial design. The influences of all machining parameters on surface roughness have been analyzed based on the developed mathematical model. The developed prediction equation shows that the most significant parameter is cutting speed followed by feed rate and lastly machining time. The result from this research is useful to be implemented in industry to reduce time and cost in surface roughness prediction.

A Sustainability Index for the Evaluation of Machining Operations

“…The academic literature shows that the surface quality affect to efficiency and sustainability because can determine the number of operations required; for this reason the roughness is a very studied variable, in particular its predictions through of the knowledge of some variables as chip size (Zuperl & Cus, 2015) or the influence of cutting parameters on different operations as milling (Qehaja et al, 2016) or drilling [Domingo et al, 2013). The tool life affects to surface quality (Kumar, 2017), therefore it is other element to consider, and moreover affect clearly to sustainability due to the material wear and to the machining time due to tool change; it is clear that to higher tool wear, the change time will higher.…”