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Advances in Materials Science and Engineering
Volume 2016, Article ID 7372132, 14 pages
http://dx.doi.org/10.1155/2016/7372132
Research Article

Optimizing Cutting Conditions for Minimum Surface Roughness in Face Milling of High Strength Steel Using Carbide Inserts

1Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
2Department of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia

Received 7 December 2015; Revised 3 March 2016; Accepted 6 March 2016

Academic Editor: Fernando Lusquiños

Copyright © 2016 Adel Taha Abbas et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

A full factorial design technique is used to investigate the effect of machining parameters, namely, spindle speed , depth of cut and table feed rate on the obtained surface roughness ( and ) during face milling operation of high strength steel. A second-order regression model was built using least squares method depending on the factorial design results to approximate a mathematical relationship between the surface roughness and the studied process parameters. Analysis of variance was conducted to estimate the significance of each factor and interaction with respect to the surface roughness. For , the results show that spindle speed, depth of cut, and table feed rate have a significant effect on the surface roughness in both linear and quadratic terms. There is also an interaction between depth of cut and feed rate. It also appears that feed rate has the greatest effect on the data variation followed by depth of cut. For , the results show that the table feed rate is the most effective factor followed by the depth of cut, while the spindle speed had a significant small effect only in its quadratic term. The conditions of minimum and are identified through least square optimization. Moreover, multiobjective optimization for minimizing and maximizing metal removal rate is conducted and the results are presented.