Tool flank wear model and parametric optimization in end milling of metal matrix composite using carbide tool: Response surface methodology approach

Highly automated CNC end milling machines in manufacturing industry requires reliable model for prediction of tool flank wear. This model later can be used to predict the tool flank wear (VBmax) according to the process parameters. In this investigation an attempt was made to develop an empirical relationship to predict the tool flank wear (VBmax) of carbide tools while machining LM25 Al/SiCp incorporating the process parameters such as spindle speed (N), feed rate (f), depth of cut (d) and various % wt. of silicon carbide (S). Response surface methodology (RSM) was applied to optimizing the end milling process parameters to attain the minimum tool flank wear. Predicted values obtained from the developed model and experimental results are compared, and error < 5 percent is observed. In addition, it is concluded that the flank wear increases with the increase of SiCp percentage weight in the MMC.