Scenario of surface roughness and material removal rate of h 13 mould steel in CNC end milling process

Milling is the most common form of machining process used in the production of moulds/dies, due to the high tolerances and surface finishes by cutting away the unwanted material. The selection of Air hardening tool steel is widely used in production of moulds/dies because of less wear resistance are used for large components. Due to extensive use of highly automated machine tools in the industry, manufacturing requires reliable models and methods for the prediction of output performance of machining processes. The major objective of the present study is modeling and analysis of machining parameters in end milling for material removal rate and surface roughness by considering the input parameters such as cutting speed, feed rate, axial-depth of cut, radial depth of cut and nose radius. The design of experiment (DOE) technique has been implemented to conduct the experiments which in turn reduced the number of experiments. The most accurate prediction models were developed using response surface methodology. The predicted results were analyzed through experimental verification. To have more precise investigation in to the models, a regression analysis of experimental and predicted outputs was performed. In order to study the main effects and interaction effects of machining parameters, analysis of variance (ANOVA) was performed. To judge the ability efficiency of the developed models, percentage deviation and average percentage deviation has been used.