Effect of process parameters in face milling operation and analysis of cutting force using indirect method

Amelioration of demand for quality in machining-related products has resulted in the manufacturing industries as cornerstone for enhancement in quality control measures of the machining process. Milling, like any metal cutting operation, is used with an objective of optimizing surface roughness. Meticulous prediction of surface quality of a particular material during face milling operation is highly important for the purpose of controlling product quality and production rate. The machining characteristics of AA6061 using face milling were investigated. To calculate the cutting force through indirect approach, during machining the data acquisition was performed using a FANUC LAN cable. The data related to the current drawn by each axis were captured under two varying cases, one “With Cut” and another “Without Cut.” The experimental plan was executed by adopting the Taguchi approach to minimize experimental cost. The results attained through analysis of variance signify that the projected mathematical model can efficiently illustrate the performance in the boundary limit of the premeditated factors.