Optimization of machining parameters on temperature rise in end milling of Al 6063 using response surface methodology and genetic algorithm

• DOI: 10.1007/s00170-012-4652-8
• Publication Date: 2012-12-07T04:59:39Z
• Authors: P. S. Sivasakthivel; R. Sudhakaran
• Keywords: Thermocouple; End mill; Central composite design

This present study focused on the effect of machining parameters such as helix angle of cutter, spindle speed, feed rate, axial and radial depth of cut on temperature rise in end milling. A prediction model of the temperature rise was developed using response surface methodology. The experiments were conducted on Al 6063 by high-speed steel end mill cutter based on central composite rotatable designs consisting of 32 experiments. The temperature rise was measured using K-type thermocouple. The adequacy of the model was verified using analysis of variance. The given model is utilized to analyze direct and interaction effect of the machining parameters with temperature rise. The optimization of machining process parameters to obtain minimum temperature rise was done using genetic algorithms. A source code using C language was developed to do the optimization. The obtained optimal machining parameters gave a value of 0.173 °C for minimum temperature rise.