Response surface methodology approach in achieving multi-response setup optimization in the machining process

Abstract

A machining cost is constructed on many factors. All aspects potentially raise the additional charges resulting from not achieving dimension due to tool wear level. The accuracy of parameters determines the effectiveness of the machining process. However, these parameters are sensitive, so the different machines may not provide the same performance. The specific machining parameters become less suitable for others. This experimental approach is proposed to obtain the parameter used on other machines without reducing the performance. This multi-response study used a response surface methodology by selecting the material removal area, feed rate, spindle speed, and the number of repetitions as input have a dominant influence on the tool wear and the dimension deviation. A comprehensive range with the specified target is obtained by applying different weights. Testing on 11 units of machines from 3 other countries provides the same performance and contributes to saving 15 % of machining time.