Abstract
The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the workpiece, extend tool life, reduce overall cost, and improve productivity. This work aims to establish the performance of end milling process parameters and the impact of trochoidal toolpath parameters on the surface finish of AISI D3 steel. It especially focuses on the effect of the tool tip nose radius deviation on the surface quality using precision measurement techniques. The experimental design was carried out in a systematic manner using a face-centered central composite design (FCCD) within the framework of response surface methodology (RSM). Twenty different experiment trials were conducted by changing the independent variables, such as cutting speed, feed rate, and trochoidal pitch distance. The main effects and the interactions of these parameters were determined using analysis of variance (ANOVA). The optimal conditions were identified using a multiple objective optimization method based on desirability function analysis (DFA). The developed empirical models showed statistical significance with the best process parameters, which include a feed rate of 0.05 m/tooth, a trochoidal pitch distance of 1.8 mm, and a cutting speed of 78 m/min. Further, as the trochoidal pitch distance increased, variations in the tool tip cutting edge were observed on the machined surface due to peeling off of the coating layer. The flaws on the tool tip, which alter the edge micro-geometry after machining, resulted in up to 33.83% variation in the initial nose radius. Deviations of 4.25% and 5.31% were noted between actual and predicted values of surface roughness and the nose radius, respectively.