Optimization of Surface Roughness in High-speed End Milling Operation Using Taguchi’s Method

This paper presents the optimization of high speed milling process parameters with respect to the surface roughness of samples and the study of the Taguchi design application to surface quality in a CNC end milling operation. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized given various control factors using fewer resources than a factorial design. An orthogonal array of L9 was used and ANOVA analyses were carried out to identify the significant factors affecting surface roughness. In the present investigation, the straight flute end-milling cutter was used for machining of Al-Si-Mg-Fe alloy work pieces. The surface roughness depends upon the cutting speed, feed rate and depth of cuts. The influence of highspeed end milling on surface roughness in Al-Si-Mg-Fe alloy work pieces, which were cast by the sand, investment and die casting method, was investigated. The results concluded that the surface roughness decreases with increase in the cutting speed, increases with increase in feed rate and depth of cut. Confirmation test with optimal levels of machining parameters were carried out in order to illustrate the effectives of Taguchi’s optimization method.