Experimental Study of Process Parameters in Milling Using Fuzzy Logic and Regression Analysis Approach

Abstract

Milling is a machining operation in which a workpiece is fed past under a rotating cylindrical tool with multiple cutting edges. The axis of rotation of the tool is perpendicular to the feed direction. The tool is called the milling cutter and the cutting edges are called teeth. Mostly plane surfaces are created through milling. It’s an interrupted cutting operation; the teeth of milling cutter enter and exit workpiece during each revolution. 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 forces in milling is often needed in machining automation. In the present study the comparison has been made between data for experimental study and software study comparing the data for variation of tool wear rate, Material removal rate and Surface hardness using MATLAB software. The objective of this study is to predict the effects of cutting parameters on the variations of cutting forces during end milling operation on vertical milling machine. A number of tests were performed with different cutting speed and feed rates. The cutting force has been measured using the piezoelectric dynamometer for varying feed rate, speed and depth of cut. The different values of cutting speed, feed and depth of cut evaluated were used as input for obtaining MRR, TWR, and Surface hardness in MATLAB 7.0 Software. Thus, Using from experimental results of cutting parameters and wear values of analytical model, fuzzy logic capabilities have been used to predict the wear rate as the force values increase. The simulation results presented with MATLAB software show the effectiveness of proposed system for tool and material wear in Milling operation. 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.