Multi-response optimisation of hard milling process parameters based on integrated Box-Behnken design with desirability function approach

The mathematical modelling and multi-response optimisation of cutting forces, work piece surface temperature and sound pressure level during hard milling of 100MnCrW4 tool steel using coated (TiN+TiAlN) carbide inserts were presented in this paper based on integrated Box-Behnken design with desirability function. The parameters that influence hard milling such as work material hardness, nose radius, feed per tooth, radial and axial depth of cut were discussed. Various test results and reliability of developed quadratic models were verified using analysis of variance (ANOVA) and they were found to be highly close to experiment and significant. The optimised results were validated experimentally and less than 2% error variation was found. Work material hardness, feed per tooth and nose radius have a significant influence on all response variables. Abrasion marks, coating peel off on the tool surface and saw tooth chips were characterised through SEM analysis. Copyright © 2014 Inderscience Enterprises Ltd.