Prediction of Tool Wear from Machining Parameters by Response Surface Methodology in End Milling

Tool wear increases cutting force, vibration, temperature, etc in end milling and reduces surface finish of the machined work piece. Mathematical model has been developed to predict the tool wear in terms of machining parameters such as helix angle of cutting tool, spindle speed, feed rate, axial and radial depth of cut. Central composite rotatable second order response surface methodology was employed to create a mathematical model and the adequacy of the model was verified using analysis of variance. The experiments were conducted on aluminium Al 6063 by high speed steel end mill cutter and tool wear was measured using tool maker’s microscope. The direct and interaction effect of the machining parameter with tool wear were analyzed, which helped to select process parameter in order to reduce tool wear which ensures quality of milling.