Prediction of cutting force based on Machining parameters on al7075 t6 Aluminum alloy by response surface Methodology in end milling

Abstract

End-milling is a sort of external milling that is widely employed in the metal cutting sector. It is used to make outer surface machining, cavities, engraves, curvatures and receptacles in a wide range of products. End-mill cutters are used to manufacture workpieces with two surfaces at the same time, one at the outer face and the other at the periphery of the cutter. The proper selection of milling process variables such as cutting speed, axial depth of cut, feed rate and so on. Cutting tool design which includes nose radius and tool angles such as relief angle, rake angle, and helix angle is a major control factor. The machining process is greatly influenced by the selection of machining parameters and the shape of cutting tools. This characteristic causes a bigger and deeper difference in surface finishing, rigidity, thermal stress during milling, cutting force need, and waste output. newlineThe surface quality of the workpiece in the integrated item is one of the most important parameters in milling which influences its effectiveness. A higher amount of wear and an elevated friction coefficient can be attributed to the existence of a rough surface finish most of the time. As a result, surface smoothness is an important aspect of determining quality standards. Inadequate cutting force can cause bending of either the workpiece or the tool, impacting the proper performance of the machine. It can also result in an uneven temperature difference on the work material, as well as inconsistent vibration. The force applied to the component is determined by several elements, including cutter geometry, speed and feed combinations, cut depth and so on. To eliminate errors and achieve the highest expected milling excellence, it is critical to have the appropriate parameters and tool design. newline