Prediction of cutting force in end-milling operation of modified AISI P20 tool steel

Abstract The present paper discusses the development of the first and second order models for predicting the cutting force produced in end-milling operation of modified AISI P20 tool steel. The first and second order cutting force equations are developed using the response surface methodology (RSM) to study the effect of four input cutting parameters (cutting speed, feed rate, radial depth and axial depth of cut) on cutting force. The cutting force contours with respect to input parameters are presented and the predictive models analyses are performed with the aid of the statistical software package Minitab. The separate affect of individual input factors and the interaction between these factors are also investigated in this study. The received second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth, and radial depth of cut and, finally, by the cutting speed. It was found that the interaction of feed with axial depth was extremely strong. In addition, the interactions of feed with radial depth; and feed rate with radial depth of cut were observed to be quite significant. The predictive models in this study are believed to produce values of the longitudinal component of the cutting force close to those readings recorded experimentally with a 95% confident interval.