Analytical Modeling of Cutting Forces of End Milling Operation on Aluminum Silicon Carbide Particulate Metal Matrix Composite Material Using Response Surface Methodology

The cutting forces exerted by the cutting tool on the work piece during a machining action to be identified in order to control the tool wear and occurrence of vibration, thus to improve tool-life. Modeling of cutting force in milling is often needed in machining automation. The objective of this study is to predict the effects of cutting parameters on the variations of cutting forces during end milling operation of Al SiC metal matrix composite material. Cutting forces are measured for varies feed rates. In this study Response Surface Methodology is used by designing four factors, five level central composite rotatable design matrixes with full replication; for planning, conduction, execution and development of mathematical models. The average cutting forces are determined at different feed rates in tangential, radial, and axial directions per tooth period by keeping immersion and axial depth of cut as constant. A comparison between modeling and experiment is presented. This model and analysis are useful not only for predicting the tool wear but also for selecting optimum process parameters for achieving the stability of the end milling process.