Comparative studies of variation in end mill radial rake angle and cutting conditions on cutting force and surface integrity during machining of nimonic 263

Abstract

Tool nomenclature has a profound effect on the machining of alloys and the cutting force during machining. In this study, the effect of changes in radial rake angle of end mill cutter (+7°,0°, -7°) and machining parameters such as spindle rotational velocity (v) and table feed velocity ( f ) on cutting force and surface roughness were presented using regression analysis and a comparison has been made with the measured surface roughness and cutting force data. Additionally, to confirm the goodness of fit, Analysis of variance (ANOVA) has been undertaken and found that the developed empirical model is significant. The experimental outcome clearly indicates that the radial rake angle of end mill cutter is the most significant parameter, which reflect higher efficiency during machining followed by table feed velocity. Spindle rotational velocity is found to be a least significant parameter. Furthermore, the analysis of chip morphology confirmed the behavioral changes while machining due to the presence of variation in tool nomenclature and machining condition.