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MODELLING AND SENSITIVITY ANALYSIS OF

SURFACE
ROUGHNESS IN HIGH SPEED BALL END MILLING

PRABAS BANERJEE
Research Scholar
NIT Durgapur
Organization of presentation
 Introduction to Ball-End Milling
 Response Surface Method
 Surface roughness recording and analysis
 Results and Discussion
 Conclusion
Ball-End Milling
The ever increasing demand on cost reduction and improving quality of final
products are driving metal cutting research into new areas. One of the most
common metal removal operations used in industry is the end milling process.
High speed ball-end milling is one of the modern technologies, which in
comparison with conventional cutting enables to increase efficiency, accuracy and
quality of product. In cutting, the cutting edge geometry of a cutting tool has a
direct influence on the cutting performance and the resulting cutting forces. The
ball-end milling process is one of the most commonly used manufacturing
process for material removal in manufacturing industries due to its versatility in
generating complex shapes of high quality and at high productivity.
APPLICATION
Ball-End milling is widely used in the following sectors:
 Automobile
 Aerospace
 Die/mold industries
 Machining of propellers and turbine blades
Response surface methodology
(rsm)
RSM is a collection of mathematical and statistical techniques that are
useful for the modelling and analysis of problems in which a response of
interest is influence by several variables and objective is to optimize this
response. RSM design also help in quantifying the relationships between
two or more measured responses and the input factors. Regression
analysis should be performed to determine an existing relationship
between the input factors and response variables statistically. The second
order polynomial in independent variable is given by:

The least square technique is being used to fit a model equation containing the
regressions or input factors by minimizing the residual error by measuring sum of square
deviations between the actual and estimated response model. This involves the regression
coefficients of the model variables including the intercepts or constant terms.
Central composite design (ccd)
The CCD is a very efficient design for fitting the second order model. This
is the most popular class of designs used for fitting these models. Generally,
the CCD consists of a 2K factorial or fractional factorial designs with nF runs
, 2K axial runs, and nc center runs. It is a sequential experimentation. There
are two parameters in the design that must be specified:
1. The distance α of the axial runs from the design center and
2. Number of center points nc.
Rotatability is important for the second order model to provide good
predictions throughout the region of interest. It is a reasonable basis for the
selection of a response surface design. A central composite design is made
rotatable by the choice of α. For the rotatability the value of α should be
equal to the (nF )1/4 which depends on the number of points in the factorial
portion of the design.
Experimentation
A set of slot milling experiments were performed on Mikron-VCP710 vertical
three axis CNC milling machine. The work material was Al2014-T6.
Cutting Tool:
TiAlN coated (monolayer) 2 flute solid carbide ball-end milling cutter of diameter
10 mm (Sandivk coromant CoroMill Plura, R216.42-10030-Al10G 1620), helix
angle 300 and rake angle 40.
Machining Parameters:
Feed per tooth (fz), axial depth of cut (Ap), radial depth of cut (Ae) and cutting
speed (Vc).
These parameters affect the cutting forces, they have been chosen as the
independent input variable. A standard RSM design called rotary central
composite design (RCCD) was used to study the slot milling process whereby the
factorial portion is full factorial with full replication of the factors at all levels. The
model consist of 16 cube points, 7 central points and 8 axial points. The value of α
was 2. The response variables studied are tangential (FX), radial (FY), axial (FZ).

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