The effect of cutting parameter on surface roughness during end milling of AISI D2 tool steel

Abdul Halim, Mohd Amal (2014) The effect of cutting parameter on surface roughness during end milling of AISI D2 tool steel. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The material of AISI D2 tool steel contains high carbon and chromium alloyed is referred as difficult material to be machining. This research was performed to identify the implications of machining variables in High Speed Machining of milling using material of AISI D2 tool steel with inserted end mill tool. The experiment work was carried out using Box-Behken techniques, a part of response surface methodology (RSM) approach by generating from the Design Expert Software. The effect of milling parameters that are cutting speed, feed rate, and width of cut were studied to evaluate their effects on surface roughness. In this study, the cutting speed, feed rate, and width of cut were in the range of 100-200 m/min, 0.1-0.3 mm/tooth, 0.2mm and 2.0-8.0 mm respectively. This study prove that the parameters that give the most significant to the surface roughness in descending order starting from cutting speed, feed rate and width of cut. The effects of input factors on the response were identified by using analysis of variance ANOVA. The responds of surface roughness then simultaneously optimized. The optimum parameters that yield the best surface roughness are cutting speed of 150 m/min, feed rate of 0.1 mm/min and the width of cut of 8mm that produce the surface roughness of 0.186 μm.

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