Investigation on Milling Quality of Stone–Plastic Composite Using Response Surface Methodology

Abstract

To improve the cutting quality of stone–plastic composites, a series of milling experiments were performed using the response surface, binary, and microanalysis methodologies, paying special attention to the effects of milling parameters (rake angle from 6° to 14°, spindle speed from 5000 rpm to 7000 rpm, feed rate from 10 m/min to 20 m/min, and milling depth from 0.5 mm to 2 mm) on the quality of the machined surface. Surface damage was mainly concentrated on the crest and two axial sides of the milling wave, with cracking and pitting identified as the main damage patterns. These experiments determined that the optimal conditions for milling stone–plastic composite with minimal surface roughness are a rake angle of 10°, cutting speed of 37.9 m/s, feed per tooth of 0.32 mm, and milling depth of 0.5 mm. The mathematical model for surface roughness developed from these results is highly reliable and could be used for the prediction and optimization of surface roughness during industrial manufacturing of stone–plastic composites.