OPTIMIZATION OF CUTTING FORCES IN END MILLING OF CFRP COMPOSITES USING RESPONSE SURFACES AND DESIRABILITY FUNCTION APPROACH

摘要

The quality of a machined product relies primarily on the setting of process parameters duringthe machining operation. To obtain desired outcome, it is vital to identify and control the processparameters which have a significant effect on the response variables. Response Surfaces is onesuch approach which utilizes statistical and optimization techniques to arrive at an optimalcombination of factor settings that can minimize the cutting forces acting on carbon fiberreinforced composite work piece. In this study the effects of process parameters spindle speed,feed rate and fiber orientation on cutting forces generated on the composite material wasevaluated. Three level factorial design, Analysis of Variance (ANOVA) and overlay contourplots were utilized to arrive at the combination of factor settings which produced minimumforces. The process parameters were tested at three different levels i.e. Speed at 500, 1000 and1500 rpm, feed rate at 50.8, 101.6 and 152.4 mm per minute and fiber orientation at 0, 30 and 60degrees respectively. The minimum forces were achieved at Speed = 905 rpm, feed = 50.8mm/min and fiber orientation = 0 degrees. The resulting optimal conditions were tested using theDerringer-Suich desirability function approach and similar results were observed. Operating atthe above optimal settings of process parameters ensures minimum forces to be acting on thecomposite material during machining and therefore results in a better surface quality.