Parametric Optimization of Trochoidal Step on Surface Roughness and Dish Angle in End Milling of AISID3 Steel Using Precise Measurements

Tool steel play a vital role in modern manufacturing industries due to its excellent properties. AISI D3 is a cold work tool steel which possess high strength, more hardenability and good wear resistance properties. It has a wide variety of applications in automobile and tool and die making industries such as blanking and forming tools, high stressed cutting, deep drawing and press tools. The novel ways of machining these steels and finding out the optimum process parameters to yield good output is of practical importance in the field of research. This research work explores an attempt to identify the optimized process parameter combinations in end milling of AISI D3 steel to yield low surface roughness and maximum dish angle using trochoidal milling tool path, which is considered as a novelty in this study. 20 experimental trials based on face centered central composite design (CCD) of response surface methodology (RSM) were executed by varying the input process factors such as cutting speed, feed rate and trochoidal step. Analysis of variance (ANOVA) was adopted to study the significance of selected process parameters and its relative interactions on the performance measures. Desirability-based multiple objective optimization was performed and the mathematical models were developed for prediction purposes. The developed mathematical model was statistically significant with optimum conditions of cutting speed of 41m/min, feed rate of 120 mm/min and trochoidal step of 0.9 mm. It was also found that the deviation between the experimental and predicted values is 6.10% for surface roughness and 1.33% for dish angle, respectively.