Abstract

The characteristic features of hard milling are variable chip thickness and intermittent cutting. Such tendency rapidly increases the tool wear and reduces the metal removal rate against the cutting temperature results poor surface finish. Therefore, the objective of this present study was to present the mathematical models for modeling and analysis on the effects of process parameters, including the feed per tooth, radial depth of cut, axial depth of cut and cutting speed on cutting temperature, tool wear and metal removal rate in hard milling of 100MnCrW4 (Type O1) tool steel using (TiN+TiAlN) coated carbide inserts. A central composite rotatable design with four factors and five levels was chosen to minimize the number of experimental conditions. Further, the reduced developed models were used for multiple-response optimization by desirability function approach in order to determine the optimum cutting parameters. These optimized machining parameters are validated experimentally and the experimental and predicted values were in a good agreement with small consistent error.

Keywords:

Central composite design, cutting temperature, desirability function, hard milling, metal removal rate, tool wear,

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Competing interests

The authors have no competing interests.

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