International Review of Mechanical Engineering (I.RE.M.E.), Vol. 6, N.

7
ISSN 1970 - 8734 November 2012

Experimentation and Prediction of Surface Roughness

of the Machining Parameter with Reference
to the Rake Angle in End Mill

G. Mahesh1, S. Muthu2, S. R. Devadasan3

Abstract – This paper presents the effect of process parameter in end milling operation to
predict surface roughness. An experiment has been conducted to observe the significance of
process parameters and influence of the radial rake angle of the tool in end mill cutter.
Mathematical model has been developed to predict surface roughness in terms of machining
parameters such as spindle speed, feed rate, radial, axial depth of cut, and rake angle of cutting
tool. The second-order mathematical models, in terms of the machining parameters, have been
developed using Response surface methodology (RSM)by designing five factors, five level central
composite rotatable design matrixes with full replication. The experiment is conducted on
aluminum Al 6063 by HSS end mill cutter, the surface roughness is measured by using Surftest SJ-
201.The direct and interaction effects of the machining parameter with surface roughness are
analyzed using design expert software. It is found that spindle speed and radial rake angle are
major factors influencing the surface roughness followed by radial depth of cut, feed rate and
axial depth of cut. The developed mathematical model is verified by confirmatory test and found to
be acceptable for the prediction of surface roughness. Copyright © 2012 Praise Worthy Prize
S.r.l. - All rights reserved.

Keywords: Radial Rake Angle, Surface Roughness, RSM, DoE, Vertical Milling Machine

Nomenclature Average surface roughness (Ra) is the arithmetic

N Spindle speed in m/min
Z Feed rate per tooth in mm/rev
X Axial depth of cut in mm
Y Radial depth of cut in mm
γ Radial Rake angle in degree
RSM Response Surface Methodology
Al-SiC Aluminum silicon carbide particulate
composite
MMX Metal matrix
DOE Design of Experiments
Ra Surface roughness
I. Introduction
In machining operations surface quality is one of the
most pertinent aspects as it is employed as the final stage
in the production cycle for improving the surface finish,
dimensional and geometrical properties of the product
[1]-[36]. Surface roughness is the most important
parameter which determines the quality of the product.
The surface quality of the orthopedic prostheses is a
parameter influencing in their life time [10].
Surface roughness is primarily dependent on
production process [30]. Surface roughness is expressed
as the irregularities of material resulted from various
machining operations.
average value of departure of the profile from the mean
line throughout the sampling length. Ra is also an
important factor in controlling machining performance.
Surface roughness is influenced by many factors such as
spindle speed, feed rate, radial and axial depth of cut,
radial rake angle, helix angle etc. The experiments were
designed taking into an account, that the majority of
parameters will affect the surface roughness [5].
In manufacturing industry, end milling is one of the
most widely used metal removal process. The quality of
surface is important as it plays a key role for the
improvement of corrosion resistance, fatigue strength and
creep life to name a few. The study on the effect of
process parameters on surface roughness is essential in
order to set the required process parameter on the
machine. Recent investigation has revealed that when
cutting speed is increased, productivity can be
maximized and surface quality can be improved [1]. The
authors [2] stated that the surface roughness increased
with increase in the feed or axial depth of cut, whilst
decreased surface roughness arrived at increase in cutting
speed. Among the various machining parameters, most
literature sources revealed that feed rate has the greatest
influence on the surface roughness [7]; [8]; [27]; [15].
However, the study by [11] proved that that the
combined variation of both feed rate and cutting speed
are able to increase the surface finish.

Manuscript received and revised October 2012, accepted November 2012 Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved

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 G. Mahesh, S. Muthu, S. R. Devadasan

I.1. Influence of Radial Rake Angle in End Mill Cutter been developed for surface roughness prediction using
RSM, validated through chi square test and to find the
Rake angle is the angle between the leading edge of a
optimum process parameters by using Genetic
cutting tool and perpendicular to the surface being cut as
Algorithm, [24].[25] investigate the effect of graphite
shown in Fig. 1. Rake angles for milling cutters are
and molybdenum disulphide as solid lubricants at the
specified in two directions, axial and radial rake angle.
contact surface between tool, work piece and tool chip
Axial rake is the cutting insert’s angle with respect to the
during machining by using end mill cutters of different
central axis of the cutter/spindle assembly. Radial rake is
tool geometry (radial rake angle and nose radius) under
the cutting insert’s angle with respect to the periphery of
different cutting speeds and feeds to attain high material
the cutter. Common configurations include (a) Positive in
removal rate. [26] experimental studies have been
both directions (b) Negative in both directions and (c)
conducted to observe the effect of tool geometry (radial
Positive in one direction and negative in the other.
rake angle and nose radius) and cutting conditions
Experimental studies have been conducted to predict the
(cutting speed and feed rate) on the quality of surface
effects of rake angle (-4, 0, 4, 8, 12, 16, 20) and helix
produced in dry milling with four fluted solid TiAIN
angles on the cutting forces variations during milling of
coated carbide end mill cutters. Mathematical models
hard materials. Rake angle becomes higher; the cutting
have been developed to predict surface roughness by
forces components become lower [6].The optimization of
using RSM. The optimization is carried out by using
cutting conditions to predict surface roughness (Ra) in
Genetic Algorithm to obtain the best possible tool
end milling involving radial rake angle is still lacking,
geometry and cutting conditions for dry milling. An
the authors [3] conducted an experiment by using end
attempt has been made to predict the process parameters
mill cutter to predict surface roughness by considering
such as tool wear and vibration by considering the
the radial rake angle (6.2°, 7.0°, 9.5°, 13.0°, and 14.8°)
significant parameters such as tool diameter, number of
combined with cutting speed and feed rate. Mathematical
flutes, rake and clearance angle, and work piece material
models have been developed to predict surface roughness
[34] and the larger positive rake angle is desirable for
using regression, to predict the optimum process
burr reduction [21].
parameters by using Genetic Algorithm. The authors [4]
The Fig. 2 shows the parameters that affects the
proposed the integrated SA-GA approach to optimize by
surface roughness. Currently, no exhaustive experimental
considering the same parameters to predict surface
investigation explores the influence of individual and
roughness. The rake angle may affect the quality of the
combined effects of the process parameters like spindle
machined surface and increase the rake angle improves
speed, feed rate, axial depth of cut, radial depth of cut
the overall quality of the machined edge [14]. Rake and
and radial rake angle on surface roughness have been
clearance angles are the most important factors among
reported [13]. In addition, the machining parameters are
the design factors. Rake angle in particular affects
not varied systematically, because of the complex
stiffness of the cutting edge and rigidity of the tool. An
interaction of the process parameters, ‘one variable at a
end mill with a positive rake angle improves machining
time’ approach cannot give a clear idea about the
ability. In general, the positive rake angle is applied to
correlation between machining parameters and surface
the conventional end mill, in case of a negative rake
roughness. Use of non-linear techniques like Design of
angle, the stiffness of the cutting edge is increased and
Experiments (DoE), fuzzy logic and neural network are
chipping suppressed [33]. Experiments are conducted to
suitable under such circumstances. Among these, the
observe the effect of tool geometry on the quality of
statistical DoE is the most effective and economical
surface produced by considering the radial rake angle as
technique to evaluate the main and interaction effects of
4°,10°, 16°, nose radius as 0.4°,0.8°,1.2° and cutting
input factors on an output response.
conditions (cutting speed and feed rate) on the machining
performance in dry milling. Mathematical models have

Fig. 1. End mill geometry design. (Source: HMT, 2001)

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 7

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 G. Mahesh, S. Muthu, S. R. Devadasan

5. Development of the mathematical model

6. Checking the adequacy of the models developed
7. Conducting the conformity test runs and comparing
the results.
8. Presenting the effects of the process parameters on
the mechanical properties in graphical form and
analyzing the results.

II.1. Identifying the Important Process Parameter

The ranges of machining conditions and tool radial
rake angle were selected from the recommendations
given by the tool manufacturer and machining data
handbook [12]. The authors discussed [20] in detailed
Fig. 2. Parameter that affects surface roughness about the description and to conduct the experiment.
[28]; [35] the parameters like cutting speed, depth of cut
So, the response surface methodology of the DoE was and feed rate are considered for their experiments and
used in the present work to explore the non-linear initial conditions are derived. [22] the values of spindle
relationship between the machining parameters and speed, radial depth of cut, tool radius, axial depth of cut
surface roughness. and feed per tooth are considered as initial conditions.
From the literature sources it is found that, the The literature sources [17]; [36]; [29]; [32]; [15]; [9];
machining of Al 6063 metal matrix composite is an [18] also revealed the selection of initial conditions. [31]
important area of research, but only very few studies Analysis of variance (ANOVA) is done to find the
have been carried out on surface roughness in end significance of machining parameters which affects the
milling. In the present study, an attempt is made to quality characteristics also to find the relative
investigate the effect of process parameters such as contribution of machining parameters in controlling the
spindle speed, feed rate, radial depth of cut, axial depth responses.
of cut and radial rake angle on surface roughness in end The independently controllable process parameters
milling using RSM approach. This methodology helps to affecting the surface roughness are identified which is
obtain best possible cutting conditions and tool geometry used to carry the experimental work and developed a
for dry milling of Al-6063 using HSS end mill cutters. mathematical model. The important controllable
The adequacy of the developed mathematical model has parameters considered for the investigation are radial
also been tested by the analysis of variance test. Design rake angle (γ), Spindle speed (N), Feed rate (Z), Axial
Expert 6.0 package is used to analyze the data and depth of cut(X), Radial depth of cut(Y).
develop the model. Table I lists the values of these five levels for each
factor values.
TABLE I
II. DOE Based on Response Surface VALUES OF THESE FIVE LEVELS FOR EACH FACTOR VALUES
Methodology Parameter Units Factor Level
(Input
-2 -1 0 1 2
Response surface method (RSM) adopts the Variables)
combination of experimental, mathematical and Spindle Speed RPM 1500 2000 2500 3000 3500
Feed Rate mm/rev 0.04 0.06 0.08 0.1 0.12
statistical techniques which are useful for the modeling Axial depth mm 0.5 0.6 0.7 0.8 0.9
and analysis of problems in which a response of interest of cut
is influenced by several variables [16]. RSM saves cost Radial depth mm 0.5 0.6 0.7 0.8 0.9
and time by reducing the number experiments required of cut
Radial Rake Degree 12 15 18 21 24
for investigation. In this technique, the main objective is angle
to optimize the responses that are influencing by various
parameters. In modeling of the manufacturing processes
using RSM, the sufficient data is collected through II.2. Development of Design Matrix
designed experimentation [19]; [23]. In general, a second
The design matrix selected for conducting the
order regression model is developed. The study can be
experiment at five levels, five factor central composite
used the following steps as per the methodology of
rotatable designs consisting of 32 set of coded conditions
Central Composite Design (CCD) in the optimization of
and comprising a half replication 24 =16 factorial design
experiments using RSM to understand the effect of
plus 6 centre points and 10 star points. The upper (+2)
important parameters:
and lower (-2) levels of all the five variables as shown in
1. Identifying the important process parameter
Table I are established by trial runs prior to the actual pre
2. Development of design matrix
defined parameters to establish the exact predicted
3. Conducting the experiments as per the design matrix
values. The intermediate levels of -1, 0, +1 of all the
4. Recording the responses

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 7

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 G. Mahesh, S. Muthu, S. R. Devadasan

variables had been calculated by interpolation. Thus all
the 32 experimental runs to allow the estimation of the
linear, quadratic and two way interactive effects of the
process parameters. Experiments are conducted at
random to avoid sickening errors indulging into the
experimental procedure.
III. Experimental Work
The test plates of size 50 mm × 50 mm × 50mm are
prepared from aluminum alloy Al 6063square block. The
chemical composition and mechanical properties of the
base material are presented in Table II and Table III,
respectively. The experiments are conducted on
MAKINO CNC Vertical Machining Center (Model-S33)
with high-speed steel end mill cutter under dry condition.
The Specification of end mill cutter is presented in Table
IV, Chemical composition is presented in Table V and
Mechanical properties are presented in Table VI. After
the investigation, the suitable levels of the factors are
used in the statistical software to deduce the design
parameters for aluminium alloy. The surface roughness is
measured by using surface roughness tester (SURFTEST
SJ- 201).
III.1. Recording the Responses
The experiment is conducted by milling the Al 6063
metal matrix composite material on a vertical Milling
machine by using HSS end mill cutter.
CHEMICAL COMPOSITION OF Al 6063 ALLOY (AS PER ASM AEROSPACE SPECIFICATION METAL INC.)
Weight Al Si Fe Cu Mn
(%)
6063 Bal 0.2-0.6 0.35 0.10
The response parameter surface roughness is
measured in terms of micro meter using surface
roughness tester (SURFTEST SJ- 201). Table VII shows
the experimental design matrix and the measured
response (Ra).
IV. Response Surface Model for the
Prediction of Surface Roughness
A rigorous analysis is carried out with the
experimental data using Design Expert V 7 software of
state ease. A second order quadratic model is developed
for the prediction of surface roughness. The model is
checked for its adequacy using ANOVA (analysis of
variance). Table VIII shows ANOVA table for the
prediction of Ra. It is observed from the Table VIII that
model is significant and the lack of fit is not significant
which infers the significance of the model. Values of
Prob> F less than 0.05 indicate model terms in
significant and values greater than 0.10indicate the
model terms are not significant. The p-value < 0.0001
represents that there is only a 0.01% chance that such
model could occur due to noise. To illustrate the
relationship between the response and the process
parameters the fitted polynomial equation are expressed
in the form of surface plots. The Table VIII also shows
the other adequacy measures R2, Adj R2 and Pred R2. The
coefficients of determination R2 indicate the goodness of
fit for the models and are nearer to 1.
TABLE II
Mg Cr Zn Ti Others each Others Total
0.10 0.45-0.9 0.1 max 0.10 max 0.10 max 0.05 0.15 max

TABLE III
MECHANICAL PROPERTIES OF Al 6063 ALLOY (AS PER ASM AEROSPACE SPECIFICATION METAL INC.)
Hardness Hardness Ultimate Tensile Yield Modulus of Ultimate Bearing Yield Poission’s Shear
Brinell Vickers Tensile Strength MPa Elasticity Bearing Strength MPa Ratio Strength
Strength MPa GPa Strength MPa MPa
73 83 241 214 68.9 434 276 0.33 152

TABLE IV
SPECIFICATION OF CUTTING TOOLS
Grade Classification Cutter Overall Length of Cutting Length of Number of Helix Angle
diameter cutter cutter Flutes Degree
mm mm mm
M2 Molybdenum series 10 100 40 4 30°
High-speed tool steel

TABLE V
CHEMICAL COMPOSITION (AS PER ASTM M2 STEEL PHYSICAL PROPERTIES)
Carbon Manganese Chromium Molybdenum Vanadium Tungsten Silicon
0.78 - 0.88 0.15 - 0.40 3.75 - 4.50 4.50 - 5.50 1.75 - 2.20 5.50 - 6.75 0.20 - 0.45

TABLE VI
MECHANICAL PROPERTIES OF GRADE M2
Annealing Cold pull Preheating Quenching temperature °C Holding Hardening Temper Modulus of
hardness hardness temperature salt-bath controlled time min medium temperature Elasticity
HBS HBS °C furnace atmosphere furnace °C GPa
235 262 788 1191 1204 5 to 15 Air cooling 522 221

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 7

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 G. Mahesh, S. Muthu, S. R. Devadasan

TABLE VII
DESIGN MATRIX AND RESPONSE
Factor 1 Factor 2 Factor 3 Factor 4 Factor 5 Response 1
Run Spindle speed (N) Feed Rate (Z) Axial Depth(X) Radial Depth(Y) Radial Rake Angle(γ), Surface roughness
RPM mm/rev mm mm Degree micro meter
1 -1 -1 -1 -1 1 0.53
2 1 -1 -1 -1 -1 0.43
3 -1 1 -1 -1 -1 0.52
4 1 1 -1 -1 1 0.50
5 -1 -1 1 -1 -1 0.58
6 1 -1 1 -1 1 0.46
7 -1 1 1 -1 1 0.53
8 1 1 1 -1 -1 0.53
9 -1 -1 -1 1 -1 0.53
10 1 -1 -1 1 1 0.51
11 -1 1 -1 1 1 0.61
12 1 1 -1 1 -1 0.49
13 -1 -1 1 1 1 0.60
14 1 -1 1 1 -1 0.48
15 -1 1 1 1 -1 0.51
16 1 1 1 1 1 0.50
17 -2 0 0 0 0 0.53
18 2 0 0 0 0 0.41
19 0 -2 0 0 0 0.55
20 0 2 0 0 0 0.58
21 0 0 -2 0 0 0.46
22 0 0 2 0 0 0.45
23 0 0 0 -2 0 0.46
24 0 0 0 2 0 0.51
25 0 0 0 0 -2 0.58
26 0 0 0 0 2 0.65
27 0 0 0 0 0 0.48
28 0 0 0 0 0 0.52
29 0 0 0 0 0 0.45
30 0 0 0 0 0 0.45
31 0 0 0 0 0 0.49
32 0 0 0 0 0 0.52

TABLE VIII
ANOVA TABLE FOR THE PREDICTION OF Ra
Sum of Mean F p-value
Source Squares df Square Value Prob> F
Model 0.088224 20 0.0044112 9.02604 0.0003 significant
A-spindle Speed 0.019824 1 0.01982351 40.5621 < 0.0001
B-Feed Rate 0.001336 1 0.001336 2.73443 0.1264
C-Axial Depth 7.83E-08 1 7.82755E-08 0.00016 0.9901
D-Radial Depth 0.001602 1 0.0016022 3.27837 0.0976
γ -Radial Rake Angle 0.004862 1 0.0048621 9.94880 0.092
AB 0.004111 1 0.0041108 8.41155 0.0144
AC 0.000103 1 0.0001030 0.21089 0.655
AD 0.000399 1 0.0003985 0.81550 0.3858
Aγ 7.34E-05 1 7.3396E-05 0.15018 0.7058
BC 0.002949 1 0.0029489 6.03411 0.0319
BD 0.001203 1 0.0012027 2.46110 0.145
Bγ 0.000206 1 0.00020587 0.42125 0.5296
CD 0.000846 1 0.0008464 1.732048 0.2149
Cγ 0.003091 1 0.0030909 6.324573 0.0287
DE 0.002046 1 0.0020459 4.186304 0.0654
A^2 0.000568 1 0.0005684 1.163054 0.3039
B^2 0.010916 1 0.0109163 22.33658 0.0006
C^2 0.001945 1 0.0019450 3.979895 0.0714
D^2 1.28E-05 1 1.28153E-05 0.026222 0.8743
γ ^2 0.029088 1 0.0290878 59.51844 < 0.0001
Residual 0.005376 11 0.0004887
Lack of Fit 0.000426 6 7.09857E-05 0.071702 0.997 not significant
Pure Error 0.00495 5 0.00099
Cor Total 0.0936 31
Std. Dev. 0.02210 R-Squared 0.94256
Mean 0.5125 Adj R-Squared 0.83813

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 7

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 G. Mahesh, S. Muthu, S. R. Devadasan

The regression equation obtain from the Design
Expert software in terms of actual factors are given:
Surface roughness (Ra) = 0.33209 + 3.48082E-005×
A - 4.67956 × B + 3.25372 × C + 0.56205 × D -
0.11719 × γ + 1.63368E-003 × A × B - 5.17353E-005
× A × C - 1.01735E-004 × A × D - 1.55774E-006 ×
A × γ - 6.91838 × B × C - 4.41838 × B × D + (1)
0.065223 × B × γ - 0.74132 × C × D - 0.050545 × C
× γ + 0.041122 × D × γ -1.76502E-008 × A2+
48.34360 × B2- 0.81626 × C2 -0.066256 × D2+
3.54175E-003 × γ2
minimum surface roughness. Under dry cutting
condition, built-up-edge chips form at a low spindle
speed between 1500 RPM to 2500 RPM resulted that the
surface roughness increases. Fig. 6 shows that if the
spindle speed increases the surface roughness decreases
and vice versa. It is is evident that the spindle speed is
between 3000RPM to 3500 RPM resulted in better
surface roughness. Figs. 7, 8 and 9 clearly indicate that
the increase in radial, axial depth of cut and feed rate
increases the surface roughness. This is due to the
contact area, metal being cut and the cutting force
increases, this makes the tool and work piece unstable
which resulted the increase in the surface roughness.

Fig. 5. Direct effect of Radial rake angle over surface roughness

Fig. 3. MAKINO CNC Vertical Machining Center (Model-S33)

Fig. 4. Surface roughness tester (SURFTEST SJ- 201)

Fig. 6. Direct effect of Spindle speed over surface roughness

V. Results and Discussion
V.1. Direct Effect of Variables
In this work, the effects of radial rake angle, spindle
speed, feed rate, axial depth of cut, and radial depth of
cut were experimentally investigated. From Figs. 5, 6, 7,
8 and 9, it is clear that the radial rake angle and spindle
speed have a significant effect on the surface roughness.
The effect of process parameters on the surface
roughness is discussed below.
Fig. 5 shows that the increase in radial rake angle
resulted in increase in the surface roughness. This is due
to the fact that the change in radial rake angle also
changes the sharpness of the cutting edge. It is evident
that the radial rake angle between 15° to 18º is to attain
Fig. 7. Direct effect of axial depth of cut over surface roughness

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 7

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 G. Mahesh, S. Muthu, S. R. Devadasan

Fig. 8. Direct effect of radial depth of cut over surface roughness Fig. 10. Surface interaction plot of spindle speed
speed and feed rate over surface roughness

Fig. 9. Direct effect of feed rate over surface roughness

Fig. 11. Surface interaction plot of spindle speed and axial depth over
surface roughness
V.2. Interaction Effect
The Interaction effect of process parameters on the
surface roughness is discussed below.
Fig. 10 shows the interaction effect of feed rate and
spindle speed on surface roughness. As the increase in
spindle speed from 1500 RPM to 3500 RPM the surface
roughness value is reduced, whereas the feed rate has the
inverse relationship on the surface roughness. From the
result it is evidenced that at lower spindle speed the
change in feed rate does not affect the roughness of the
milling surface but at higher spindle speed the change in
feed rate has a significant effect. Hence it can be
concluded that at higher spindle speed a lower feed rate
has to be chosen for quality surface finish. The inference
can also be verified from the ANOVA Table VIII. Fig.
11 shows the interaction effect of spindle speed and axial Fig. 12. Surface interaction plot of spindle speed and radial depth over
depth on surface roughness. It is noticed that at lower surface roughness
spindle speed the increase in axial depth has a significant
influence on surface roughness whereas at higher spindle However it is found that the interaction effect between
speed the variation in axial depth does not significantly spindle speed and radial depth have not played a
affect the surface roughness. This is due to the fact that significant role. Fig. 13 shows the interaction effect of
the higher torque produced at lower spindle speed has spindle speed and radial rake angle on surface roughness.
distorted the material surface with axial loading. The surface roughness is significantly higher at rake
Fig. 12 shows the interaction effect of spindle speed angle between 18 and 24 degrees. The similar trend is
and radial depth on surface roughness. From the Fig it is observed at all spindle speeds. The result showed that the
seen that both spindle speed and radial depth are industry preferring a good surface roughness has to fix
influencing on the effect of the surface roughness. the radial rake angle between 13 and 18.

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 G. Mahesh, S. Muthu, S. R. Devadasan

It is interesting to observe that if the radial rake angle

was in the region between 13 and 18 the milling process
will produces a good surface roughness even at all axial
depth of cut.
The higher as well as lower radial rake angle produced
maximum surface roughness. Thus the result showed an
optimum rake angle should be preferred for a good
quality finish in end milling process. Interaction effect of
radial depth and radial rake angle on the surface
roughness are depicted in Fig. 19, as observed from the
trend of axial and radial rake angle, the similar trend is
also noticed between radial depth and radial rake angle
on surface roughness.
Fig. 13. Surface interaction plot of spindle speed and radial rake angle
over surface roughness

Fig. 14 shows the interaction effect of feed rate and

axial depth on surface roughness. It is evidenced that the
interaction effect between axial depth and feed rate have
a greater influence on surface roughness.

Fig. 15. Surface interaction plot of feed rate and radial

Fig. 14. Surface interaction plot of feed rate and axial depth over
surface roughness

It is noticed that at a higher feed rate along with axial

depth of cut between 0.7 and 0.9 mm the surface of the
material is distorted and produced higher surface
roughness. Interaction effect of feed rate and axial depth
on surface roughness is shown in Fig. 15. Higher feed
rate and radial depth, increases the surface roughness
Fig. 16. Surface interaction plot of feed rate and
whereas lower feed rate and radial depth decrease the
radial rake angle over surface roughness
surface roughness. To obtain the quality surface of Ra
between 0.37 and 0.28 feed rate less than 0.09 and redial
depth less than 0.7 should be preferred. Interaction effect
of feed rate and radial rake angle on the surface
roughness are depicted in Fig. 16. The surface roughness
'Ra' is converged in all means from the maximum to a
minimum value at the region of feed rate (0.07 - 0.05)
and radial rake angle (18-15).Interaction effects of axial
depth and radial depth on the surface roughness are
depicted in Fig. 17. In order to get better surface finish
axial depth of cut and radial depth of cut should be
minimum as far as possible. Comparing the factor axial
and radial depth of cut, the axial depth of cut has an
exponential trend on the surface roughness. Interaction
effect of axial depth and radial rake angle on the surface Fig. 17. Surface interaction plot of axial depth and radial depth over
roughness are depicted in Fig. 18. surface roughness

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 G. Mahesh, S. Muthu, S. R. Devadasan

Fig. 18. Surface interaction plot of axial depth and radial rake angle Fig. 19 Surface interaction plot of radial depth and radial rake angle
over surface roughness over surface roughness

TABLE IX
VALIDATION OF THE MODEL
Trial A: B: C: D: E: Surface roughness % error
spindle Speed Feed Rate Axial Radial Radial Rake Predicted - DoE Experimental value
Depth Depth Angle model
RPM mm/rev mm mm Degree micro meter micro meter
1 3500 0.06 0.6 0.6 15 0.46 0.47 2.17
2 2500 0. 12 0.7 0.7 18 0.48 0.49 2.08
3 2000 0.04 0.5 0.9 24 0.52 0.53 1.9
4 2770 0.08 0.9 0.5 18 0.49 0.50 2.04

VI. Validation of the Model
A regression model developed using CCD of RSM of
DoE was verified using confirmatory test. Table IX
shows the comparison of predicted Vs experimental
value of the surface roughness. The percentage of error is
found to be within ±2% which shows the validity of the
model.
(15-18 degrees).
¾ The higher as well as lower radial rake angle
produced maximum surface roughness.
¾ At lower spindle speed the change in feed rate did not
affect the roughness of the milling surface but at
higher spindle speed the change in feed rate had a
significant effect.
¾ A feed rate less than 0.09 and radial depth less than
0.7 could be preferred for obtaining good surface
finish.

VII. Conclusion
Based on the experimental investigation on surface
roughness of end milling process considering the factors
such as Spindle Speed, Feed Rate, Axial depth of cut,
Radial depth of cut and Radial Rake angle using design
of experiments concept, the following conclusions are
drawn:
¾ The regression model using DoE resulted from the
experimental data can be used to predict surface
roughness 'Ra'.
¾ The Spindle Speed and Radial Rake angle are the
most important parameters to be considered for better
surface roughness of the end milling process
compared to the other factors such as Radial depth of
cut, Feed Rate and Axial depth of cut.
¾ A good surface roughness was obtained at the radial
rake angle (15-18 degrees) and spindle speed (2750-
3500 rpm).
¾ The surface roughness 'Ra' is converged in all means
from the maximum to a minimum value at the region
of feed rate (0.05 - 0.07 mm) and radial rake angle
Acknowledgements
The authors are grateful to the Management,
Department of Mechanical Engineering and Department
of Production Engineering, PSG College of Technology,
Coimbatore, India for extending the facilities to measure
the surface roughness and vibration amplitude in FIST
laboratory and Tool and die design centre to carry out
this investigation.
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Authors’ information
1
Department of Mechanical Engineering,
EASA College of Engineering and Technology,Coimbatore,
India.
E-mail: msv240606@gmail.com
2
Department of Mechanical Engineering,
Sri Vidya College of Engineering College &Technology,
P.Kumaralingapuram,
Virudhungar-626005,
India.
E-mail: smuthu231155@gmail.com
3
Department of Production Engineering,
PSG College of Technology,
Coimbatore, India.
E-mail: devadasan_srd@yahoo.com
International Review of Mechanical Engineering, Vol. 6, N. 7
 G. Mahesh, S.
S Muthu, S. R.
R Devadasan

Mahesh h G. receivedd his Bacheloor of Devadasan S S. R. is a Prrofessor in thee

Engineeering degree in Mechanical
Engineeering from P.S.N.A
P Collegee of
Engineeering and Teechnology, Kaamaraj
Universsity, Madurai, Inddia in 1998, Masster of
Engineeering degree in Production
P Engineeering
from Thiagarajar
T Colllege of Engineeering,
Kamaraaj University, Madurai, India in 2003.
He is currently a Research Schholar in the depaartment of Mechanical
Engineering, Anna
A University, Chennai, India. He has 14 yeaars of
academic experrience at various capacities. Curreently he is workiing as
an Assistant Prrofessor in the deepartment of Meechanical Engineeering,
EASA College of o Engineering annd Technology, Coimbatore,
C India. His
areas of interestt are Production Engineering, Opptimization techniques,
Vibration, TPMM etc.
Production Enngineering Depaartment of PSG G
College of Tecchnology, Coimb batore, India. Hee
holds a Bacchelor’s degree in Mechanicall
Engineering, a Master’s degrree in Industriall
Engineering, a Ph.D. degree in Mechanicall
Engineering annd a Doctor of Science
S degree inn
Mechanical Enngineering. He has h 20 years off
hing and researchh experience. Hee has published over
teach o 85 papers inn
intern
national journals. He is an editoriial advisory boarrd member of thee
Euroopean Journal off Innovation Management. His researchr interestss
inclu
ude Agile Manufaacturing, Six Sigmma, Total Producttive Maintenancee
and Total
T Quality Maanagement.

Muthu S. S received his Baachelor of Engineeering

degree inn Production Enngineering from PSG
College of
o Technology, Coimbatore,
C Univversity
of Maddras,, India inn 1978, Masteer of
Engineering degree in Industrial
I Engineeering
from PSG G College of Tecchnology, Coimbbatore,
Universitty of Madras, Inndia in 1980,a Ph.D.
degree inn Mechanical Enggineering. He is a Life
member of ISTTE, IE and Fellow w member in IIIIE. He has 30yeaars of
academic experiience at various capacities. Curreently he is servingg as a
principal in Srri Vidya Collegge of Engineeriing and Technoology;
Virudhunagar. He published 5 International Joournals and pressented
47national and International Conferences. He has been guidinng 14
Research scholaars and his areas of interest are Prroduction Engineeering,
Quality Manageement, Maintenannce Management etc.

Copyright © 20012 Praise Worthyy Prize S.r.l. - Alll rights reserved Internationnal Review of Mecchanical Engineeering, Vol. 6, N. 7

1428