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Procedia CIRP 84 (2019) 861–867
www.elsevier.com/locate/procedia

29th CIRP Design 2019 (CIRP Design 2019)

Design and Optimization of Machining Parameters for Effective AISI P20

Removal Rate during Milling Operation
*Daniyan, I. A.a, Tlhabadira, I.,b Daramola, O. O.c and Mpofu K.a
a
Department of Industrial Engineering,Tshwane University of Technolgy, Pretoria 0001, South Africa*
b
Department of Mechanical & Mechatronics Engineering,Tshwane University of Technolgy, Pretoria 0001, South Africa
Department of Metallurgical and Materials Engineering, Federal University of Technology, Akure, 340001, Nigeria
c

c
Institute of NanoEngineering Research (INER), Department of Chemical, Metallurgical and Materials Engineering (Polymer Technology Division) and the
Tooling Centre Soshanguve Campus, Tshwane University of Technology, Pretoria 117, South Africa

* Corresponding author. Tel.: +27 (064) 541-3537 E-mail address: afolabiilesanmi@yahoo.com

Abstract

Tool geometry and selection of appropriate machining parameters are important considerations that determine the quality of su rface finish, rate
of tool wear, production cycle time, rate and ease of machinability. In this study, the milling process was designed to optimize the effects of
machining parameters namely; the width of cut, cutting force, depth of cut and feed rate for effective AISI P20 removal during milling operation.
The numerical design was carried out using the Complete Abaqus Environment (CAE) and the Response Surface Methodology (RSM)
while the physical experiment was investigated using the DMU 80 CNC milling machine as well as the dynamometer and dynaware data
acquisition system. The design of the numerical experiment consists of four factor-two level factorial of 16 experimental runs. Based on the
feasible combination of the machining parameters from numerical experiment, the milling operation of AISI P20 was carried out on the DMU
80 milling machine limited to a maximum load of 900 kg. The resulting values of the cutting force, moment of force and machining time were
obtained via the data acquisition system. The analysis of the results led to the formulation of a predictive model that correlates the rate of material
removal (RMR) as a function of the independent machining process parameters. The results obtained also indicate that the cutting force, wid th
and depth of cut as well as the feed rate are important parameters that influence the rate of material removal during machining operations, hence,
the need for proper process design and control of the milling operation process parameters in order to reduce the total manufacturing time and
increase the metal removal rate which is a function of productivity. This will in turn reduce the total manufacturing cost without sacrificing
product quality with attendant increase in productivity.

© 2019 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the CIRP Design Conference 2019.

Keywords: machinability, model, process design, productivity, RMR

1. Introduction
Process design is key in the development of sustainable
manufacturing process. The process design considerations
for effective milling operations involves the cutting force,
machine and tool geometry such as the lead angle, rake
angle, clearance angle, cutter diameter as well machining
parameters such as the cutting speed, feed rate, width and
depth of cut. Other critical considerations include; the
process control, ergonomics and safety [1-3]. Proper process
design brings about the overall improvement and
optimization of the manufacturing process with resulting
reduction in the manufacturing cost, greater economic and
production efficiency as well as the repeatability of the
manufacturing process. This is essential because of the
increasing requirements and complexities of the machining

2212-8271 © 2019 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the CIRP Design Conference 2019.
10.1016/j.procir.2019.04.301

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 862 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867
operations with emerging technologies. Cutting force
measurement during machining operations has been
identified as one of the important and basic steps for effective
process control and improvement. This is because the cutting
force determines the rate of material removal, tool geometry,
chip formation, cutting temperature, tool wear, power
consumption, and quality control of the finished products [4-
6]. The force sensors has been identified as the best
alternative for monitoring tool wear, power consumption and
machining temperature during machining operations, hence,
its selection should be based on its rigidity, sensitivity and
accuracy [7]. For production and environmental
sustainability, there is need to reduce the power consumed
during machining operations via appropriate process design
[8-10]. Hence, for manufacturing industries to remain
competitive in the market, the process design must be
effective enough to bring about economy of the whole
process [11-13]. In other words, the CNC machines have to
be operated in such a way that it would be time and cost
effective, through the selection of optimum tool geometry,
and machining parameters. Many approaches have been
employed by previous researcher to optimize the machining
parameters such as the geometric and dynamic
programming, Generic Algorithm (GA), Hybrid Algorithm
(HA), Taguchi, Response Surface Methodology etc. [14-17],
According to Tomov et al., [18] and Qehaja et al. [19]
machining parameters significantly influence the degree of
surface roughness, tool integrity and product finish
requirement. An increase in the cutting speed, feed rate and
depth cut during machining operations beyond the optimum
often leads to increase in temperature and rate of chip
formation [20-22]. When chips are formed at high
temperature on the surface of the metal, if not removed
intermittently, may cause surface roughness, reduction in the
tool life and cutting integrity.
In milling operations, process design also takes tool
orientation into consideration because the multi-cutting edge
has to be geometrically defined since it performs the cutting
movements while the spindle head or the machine table
performs the feed movement depending on the type of
machine tool.
This work focusses on the application of numerical and
physical experiments in the design of milling process in order
to optimize machining parameters for effective AISI P20
removal rate. This is because the milling process is a versatile
process involving complex operations, thus, the product,
surface and tool integrity largely depends on effective design
of its manufacturing process. According to Owodunni and
Pinder [23], over the years, the selection of machining
parameters were based on the machinist’s experience, which
is unreliable and not scientifically justified. The successful
completion of this work provides both the numerical and
physical experimental justification for the election of
machining parameters.
2. Method
2.1 Process design considerations
The process design considerations for CNC milling
machining comprises of the following; material selection,
process selection, process sequencing, machine and tool
This is a resupply of March 2023 as the template used in the publication of the original article contained errors. The content of the article has remained unaffected.
selection, product finish requirements, cost and time
estimation, selection of machining parameters, programming
and cutting operation.
Materials are selected based on the requirements of the final
products. Hard and highly dense materials are often
machined at low cutting speed and feed rates with resulting
increase in the machining time and power consumption
whereas less dense materials can be machined both at high
cutting speeds and feed rates with resulting reduction in
machining time as well as lower power consumption. For
process selection, for instance, for face milling operations the
cutter needs to travel across the work piece and retracts
unlike in the end milling operation resulting in increase in
machining time as well as power consumption in contrast
with end milling operation. Fig. 1 shows the flowchart for the
design and optimization for effective material removal
during cutting operation.
Fig. 1: Flow chart for effective cutting operation
The followings are the process design considerations for
cutting tool geometry for effective face milling operations:
number of teeth, cutter diameter, the lead angle, rake angle,
end relief angle and rose radius amongst others.
a. Cutter diameter
The cutter diameter is the overall diameter of the cutter body
while the effective diameter of a milling cutter is the
maximum flat width of face to be machined by a cutter (Fig.
2). The appropriate cutter diameter depends on the width of
cut, spindle speed and machine power. For face milling
operation, it is desirable for milling cutter diameter to be
twice greater than the desired width of cut in order to provide
an effective negative entry angle between the insert and the
point of contact. In order to minimize the torsional deflection
while maintaining good rigidity when machining at high
speed, the spindle size is often decreased in order to reduce
the rotational mass and the cutter diameter. When a wide
surface is to be cut, the cutter diameter that matches the
spindle speed should be selected with the operation
performed in multiple passes. The number of inserts is
determined by the diameter and pitch of cutter. Increase in
 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867
the number of inserts tend to reduce the surface roughness
but increases the power consumption.
Fig. 2: Cutter diameter
b. The lead angle
The lead angle is the approach angle of the cutting edge with
respect to the work piece, which is measured off the cutter
axis. The relationship of the lead angle with the cutter and
spindle axis determines the performance, productivity,
quality of surface finish as well as the burring and chipping
characteristics at the exit side during the rotation of the
cutter. Burring and cutter occurs when the feed forces exceed
the strength of the work piece. The lead angle also controls
the balance between the radial and axial feed thus, increase
in the lead angle decreases the radial forces with increase in
the magnitude of the axial force. The engagement between
the cutting tools insert and work piece is determined by the
lead angle. Large lead angle leaves large face clearance with
little face engagement with resulting decrease in the tool life
and vice versa. Hence, a small lead angle will bring about a
large overall contact area with increased too life. Also, the
chip thickness increases with large lead angle and vice versa.
For square shoulder milling operation, a lead angle of 90 o is
usually desirable which places the forces completely in the
radial plane while for centre milling operations, a 45o lead
angle is desirable which places the forces equally in the
radial and axial direction. The lead angle is expressed by
Equation 1.
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 ×𝑝𝑝𝑝𝑝
𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = (1)
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 ℎ𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎
c. Rake angle
The rake angle represents the angle of inclination of the top
surface of the cutting edge measured in the axial or radial
planes. For milling operations, the rake is usually designed
independent of the lead angle and can be positive, neutral or
negative. Neutral rake indicates that the face of the cutting
tool inserts lies on the radial centre line of the cutter or that
the cutting edge and the face of the inserts lie on the axial
centre line of the cutter. On the other hand, the positive rake
is an indication that the cutting edge is on the radial centre
line of the cutter or on the axial centre line while the negative
rake indicates the fact that the cutting edge is on the radial
centre line of the cutter or that the cutting edge is positioned
on the centre line of the cutter with the top surface of the
cutting edge sloping forward from the axial centre line.
Axial rake angle determines the tangential cutting forces,
which in turns determines the rate of power consumption.
Milling cutters with higher positive rake will consume less
power than negative axial rake or lower positive rake angles.
Also, the cutting edge of the tool can be strengthened using
a negative but radially raked cutting tool which allows for the
optimization of the cutting speed and tool life.
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863
d. Helix angle
The helix angle determines the surface finish, effect of
vibrations, efficiency of machining as well as its associated
costs (Fig. 3). When the helix angle of a mill cutter is large,
the axial force on the end mill tends to increase with decrease
in the radial force and vibration while maximizing chip
evacuation. At 45o, the components of both the radial and
axial components becomes equal. However, the tool
becomes weaker. On the other hand, cutting at a smaller helix
angle makes the cutting tool stronger but with increase
surface roughness, hence, the selection of the appropriate
helix angle also depends on the materials being cut. While
smaller helix angle are recommended for heavy cut where
tolerance and surface finish is not important, larger helix
angle are often desirable for finishing operations.
The following are the recommended helix angle depending
on the materials to be cut [24].
i. Steel (30o), stainless steel (30o), brass (13o),
plastic (40o), zinc (40o), copper (40o), titanium
(30o), aluminium (45o)
Fig. 3: Influence of helix angle on cutting force and chip formation [25].
e. End relief angle
This is the relief angle behind the cutting edge which
prevents the interference of the cutting tool and the work
piece. It determines the thickness of the chips. Smaller end
relief angle promotes thin chips as well as small cutting
impact and vice versa.
f. Nose radius
Cutting forces tends to decrease with increase in the nose
radius as well as increase in edge serration in chip
morphology irrespective of the cutting speed. The surface
roughness also tend to reduce because of more surface
contact length between the work piece surface and the nose
radius leading to a stronger cutting edge. It is desirable to
always choose a nose radius that is smaller than the depth of
cut because of vibration tendencies. Smaller nose radius is
ideal for small depth of cut as it reduces vibration but with
resulting weak cutting edge. However, large nose radius is
often ideal for heavy feed rates, large depth of cut resulting
in stronger cutting edge and sometimes vibration.
The geometry of the mill cutter are shown in Fig. 4a & b.
 864 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867
(4a)
(4b)
Fig. 4a & b: Cutting tool geometry for face milling [26]
The followings are some of the cutting conditions for
effective face milling operations: cutting force, feed rate,
depth of cut, cutting speed, spindle speed, width of cut, and
feed per tooth.
i. Cutting force
In the selection of effective face mill, the determination of
the right cutting force is important because it differs with
each combination of rake angle. The rake angle determines
the cutting force required to separate the chip from the work
piece material while the combination of the rake angle and
the cutting tool insert rake surface determine the force
required to slide the chip along the rake face. Cutting forces
falls into three categories; the radial or axial forces, feed and
tangential forces. The radial or axial forces which pushes the
tool away from the work piece in the axial or radial direction
and accounts for approximately 10% of the total cutting
forces. On the other hand, the feed forces acts directly on the
tool in the direction parallel to the direction of the feed and
accounts for about 20% of the total cutting forces during
machining operation. This is determined by the cutter
rotation and the feed direction. In order to decrease the feed
forces and power consumption, the climb milling and spindle
power are often designed to provide feed motion while using
the feed mechanism to control the feed rate. Also, the
tangential forces acts on the rake face of the milling cutter in
the direction of the cutting velocity and accounts for about
70% of the total forces generated during the milling
operation. The selection of a cutter with large positive axial
rake decreases the tangential forces while the ones with large
negative rake tends to increase the tangential force.
ii. Cutting speed
The cutting speed 𝑉𝑉 is a measure of the relative velocity
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between the cutting tool and the work piece and its selection
depends on the type of material and the cutting tool. Cutting
tool increases with increase in the work piece hardness and
vice versa. It determines the rate of material removal, power
requirement and surface finish. When the cutting speed is
high, it tends to reduce the surface roughness and machining
time, but with resulting reduction in the tool life and vice –
versa. It is expressed as Equation 2.
𝜋𝜋𝜋𝜋𝜋𝜋
𝑉𝑉 = 1000 (2)
Where 𝐷𝐷 is the diameter of the work piece (mm) and 𝑁𝑁 is the
spindle speed (rpm).
iii. Feed per tooth
The feed per tooth is the distance the work piece is fed into
the cutter as each tooth rotates which is expressed as
Equation 3.
𝑓𝑓
𝑓𝑓𝑡𝑡 = 𝑁𝑁 𝑟𝑟𝑛𝑛 (3)
𝑡𝑡
Where; 𝑛𝑛 is the number of teeth and 𝑓𝑓𝑡𝑡 is the amount of
material is removed per individual tool tooth during milling
operation (mm), 𝑓𝑓𝑟𝑟 is the feed rate (mm/min)
iv. Feed rate
The feed rate is the relative velocity travelled by the cutting
tool along the work piece in one spindle revolution. It
depends on the depth and width of cut type of cutter, work
piece material, finish and precision requirements as well as
the power and rigidity of the machine, tool and work piece.
Equations 4 and 5 respectively express the approach
allowance for peripheral and face milling.
𝐴𝐴 = √𝑑𝑑(𝐷𝐷 − 𝑑𝑑) (4)
Where; 𝐴𝐴 is the approach allowance (mm), 𝐷𝐷 is the cutter
diameter (mm) and 𝑑𝑑 is the depth of cut (mm)
𝐴𝐴 = 𝑂𝑂 = 𝐷𝐷⁄2 (5)
Where; 𝑂𝑂 is the cutter run out diameter (mm)
Equation 6 expresses the rate of material removal.
𝑀𝑀𝑟𝑟 = 𝑤𝑤. 𝑑𝑑. 𝑓𝑓𝑟𝑟 (6)
Where; 𝑤𝑤 is the width of cut (mm); 𝑑𝑑 is the depth of cut
(mm) and 𝑓𝑓𝑟𝑟 is the feed rate (mm/min).
2.2 Process simulation
This is a mathematical and statistical tool that can be
employed for experimental modelling and analysis of
problems in which a response of interest is influenced by
several variables and also to determine its optimum condition
[27]. The production process often employs process
simulation tools ranging from numerical experimentation
tools to CAD systems in order to improve the overall process
operation and delivery as well as to optimize cost and
machining time (Fig. 5). The model was built in the
Complete Abaqus Environment (CAE) which provides the
analysis tool (ABAQUS/Standard) used for modelling the
initial thermal and mechanical loads. The modelling and
simulation assists in the determination of the final stress,
strain and temperature profiles in the test piece. With the
process simulation tools, the relationships between the
process parameters (depth of cut, cutting speed, width of cut,
feed rate, feed per tooth, cutting force, spindle speed etc.) on
a measured response such as energy consumption, rate of
 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867 865

material removal, machining time, surface roughness etc. can
be determined. Often times, the selection of machining
parameters are determined through the machinist experience
but the use of process simulation tool can help to optimize
the process parameters for improved machining
performance.
temperature is high enough to cause plastic deformation at
the tool-work piece interface for shearing action to take
place. Also Fig. 8, indicate that the temperature distribution
of the work piece spreads from room to melting temperature
(1369oC) while that of the cutting tool ranges from room
temperature to 300oC (Fig. 9). This indicate that the cutting
tool possess greater hot–hardness that the work piece, and as
such, demonstrates sufficient ability to cut the work piece
under high temperature.

Fig. 5: CAD of the milling process

2.3 Design of numerical Experiment

Design of experiment (DOE) is a technique, which correlates
Fig. 7: Temperature distribution at the tool-work piece interface
the response output as a function of independent process
parameters. This tool is cost effective when employed in
design, manufacturing as it speeds up the process of design,
and minimise expensive experimental runs [28].
DOE was set up in this study to understand the influence of
depth of cut and feed parameters on the material removal rate
during the machining of AISI P20. The statistical analysis of
the results obtained brought about a predictive model using
the Design Expert (version 8, State-Ease) based on Response
Surface Methodology (RSM) with Central Composite
Design (CCD) for process optimisation.
Fig. 8: Temperature distribution over the work piece
2.4 Physical Experiment for the case study
The experiments were carried out using a
DMU80monoBLOCK Deckel Maho 5-axis CNC milling
machine at Tshwane University of Technology at the
Department of Institute for Advanced Technology. A 2-flute
SANDVIK cutting tool of diameter 16 mm with inserts
R390-11 T3 08-PM of grade 1130 was employed for material
removal of the AISI P20 work piece (Fig. 6).

Fig. 9: Temperature distribution over the tool

The statistical analysis of the results obtained from the

Fig. 6: The physical experimental set up
3. Results and Discussion
Fig. 7-9 show the temperature distribution of the tool-work
piece interface, work piece and cutting tools. Fig. 7 indicate
that the maximum temperature at the tool-work piece
interface is 1590oC. This exceeds the plastic deformation
temperature of the work piece (750 oC -850 oC) hence the
Response Surface Methodology (RSM) was used to
predictive model that correlates the rate of material removal
as a function of the cutting speed and the feed rate expressed
by Equation 6.
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑜𝑜𝑜𝑜 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = +1332.10 + 263.62𝐴𝐴 −
63.79𝐵𝐵 + 201.16𝐴𝐴𝐴𝐴 + 76.19𝐴𝐴2 + 110.56𝐵𝐵2 (6)
Where; A represents the cutting speed (mm/min), and B is
the feed rate (mm/rev).
The combination of process parameters by numerical
experiment whose rate of material removal was determined
experimentally is presented in Table 1.

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 866 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867

cause heat and stress to build up around the cutting tool

Table 1: Numerical and physical experiment thereby reducing the quality of surface finish.
Run Factor Factor 2: Actual Rate Predicted
1: Feed rate of material rate of
Cutting (mm/rev) removal material
speed (mm3/min) removal
(m/min) (mm3/min)
1. 256.89 1500 805.776 806.001
2 267.50 1500 1250.34 1252.021
3 260 2200 709.856 708.999
4 278.11 1500 2300.68 2300.323
5 267.50 1500 1680.56 1680.400
6 267.50 2489.95 1450.77 1448.290
7 267.50 510.05 908.678 907.246
8 275 2200 1109.6 1111.862
9 260 800 1750 1753.670
10 267.50 1500 1670.45 1668.200
11 275 800 1345.77 1347.009
12 267.50 1500 1505.55 1508.231
13 267.50 1500 1908.6 1910.15
Fig. 11: 2D plot of effect of feed rate and cutting speed

The validation of the developed model was done by

comparing its predicted out put with the experimental results.
Fig. 10 shows that there is good agreement between the
actual and the predicted values of the rate of material
removal. This indicates that the developed model is highly
significant and adequate for predictive purpose.

2500
Rate of material removal (mm3/min)

2300
2100
1900
1700
1500
Actual
1300
Predicted
1100
900 Fig. 12: 3D plot of effect of feed rate and cutting speed

700
500
0 1 2 3 4 5 6 7 8 9 1011121314
Experimental runs
Fig. 10: Actual and predicted values of the rate of material removal
Fig. 11 and 12 are the 2D and 3D plots which show the effect
of feed rate and cutting speed on the rate of material
removal. An increase in the cutting speed and feed rate
increases the rate of material removal and vice versa. The
demerits being increase in power consumption as well as
reduction in the tool life. The optimum material removal rate
was found to be 1705.75 mm3/min at a maximum feed rate
of 2200 mm/rev and cutting speed 275 m/min. An increase
in the speed and feed rate beyond this optimum point may
4. Conclusion
The design and optimization of the machining process and
parameters for effective rate of removal of AISI P20 during
milling operation was carried out. The flow chart, which
integrates the process design processes, was also presented.
In addition, the process simulation was carried out using the
Complete Abaqus Environment for the determination of the
temperature distributions around the cutting tool, work piece
and tool-work piece interface while the Response Surface
Methodology was employed to study the interactive effects
of the cutting speed and feed rate. The results obtained
indicates that the cutting tool can optimally perform the
cutting operation while the feed rate and cutting speed are
critical parameters that influences the rate of material
removal and surface finish. This work, which finds

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 I.A. Daniyan et al. / Procedia CIRP 84 (2019) 861–867 867

application in the manufacturing sector, presents Energy Eng., 2016, 4(2):8–16.

mathematical model equation for the process optimization of
milling operation in order to reduce the total manufacturing
cost without sacrificing product quality with attendant
increase in productivity. Future work can consider the
integration of geometric and dynamic programming such as
the Generic Algorithm (GA) or Hybrid Algorithm (HA) with
the Response Surface Methodology (RSM) for milling
process optimization
5. Acknowledgement
The researchers acknowledge the Technology Innovation
Agency (TIA) for availability of equipment and fund of the
research. Thanks to Mr. Vusi Skosana of TIA: Head of
Technology Stations.
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This is a resupply of March 2023 as the template used in the publication of the original article contained errors. The content of the article has remained unaffected.