Study Of The Effect Of Machining Parameters On End Milling Cutting Force Of Hardened 65 Manganese Steel
Manganese steel being the toughest steel commercially available is widely used in railroad rails, rock crushing machinery etc. It is characterized with high strength, ductility, toughness and excellent wear resistance in the most punishing application as well as quick work hardening. This properties makes it one of the difficult to machine materials because its machinability is usually accompanied with low productivity occasioned by high cutting force, high cutting temperature, poor surface quality and short tool life. Accordingly, the use of convectional cutting fluid is a common technique for improving machinability and has been acknowledged since early 20th century. However the environmental and health hazard associated with these cutting fluids together with developing governmental regulations have necessitated for green manufacturing system of production. In view of the above, the main work of this paper include the investigation of the effect of the machining parameters like speed, feed and depth of cut on the cutting force in the end milling of hardened 65 Manganese steel (45 HRC), with carbide end mill, under dry cutting process, using one factor at a time design of experiment (DOE). With the aid of Origin pro 8.0 software, the graphical representations of the performance indices with respect to the input parameters was presented and Response Surface Methodology (RSM) was used to analyze the performance of these parameters in respect to the cutting force. The results of Analysis of variance (ANOVA) shows that Depth of cut was the most influential factor. Accordingly, within the range of values selected for the test, the parameters were optimized and the empirical formula for the cutting force was established.
Keywords: Cutting Force, Empirical Formula, Surface Roughness, Anova, Doe, Rsm.