Optimization of cutting forces in high-speed ball-end milling using fuzzy-based desirability function approach

In the present research, a fuzzy-based desirability function approach is employed to optimize cutting parameters in high speed ball end milling process. Feed, axial depth of cut, radial depth of cut and cutting speed are selected as independent cutting parameters and responses are tangential (Fx), radial (Fy) and axial (Fz) cutting force components. Experiments are conducted using a central composite design based on response surface methodology. Individual desirability of each response is obtained using lower the better and imported to a fuzzy inference system as input and transformed into a multi-performance characteristic index (MPCI). Analysis of variance (ANOVA) for MPCI is done to study the influence of cutting parameters and composite desirability approach is used to obtain optimal cutting parameters. ANOVA reveals that axial depth of cut is the most influencing parameter accounting 47.91% followed by feed and radial depth of cut accounting 19.87% and 12.88% respectively. Cutting speed is the least influencing parameter accounting for 9.05%. The optimal setting of cutting parameter is feed 0.06 mm/rev, axial depth of cut 0.73 mm, radial depth of cut 0.35 mm and cutting speed 164.25 m/min and optimal value of corresponding force components are 37.61 N, 16.17 N and 26.52 N for Fx, Fy and Fz respectively.