GOVERNMENT COLLEGE OF ENGINEERING, JALGAON

Department of Mechanical Engineering

A Project Report on
“MACHINING PROCESS IMPROVEMENT OF CNC MACHINING OF
CONCAVE AND CONVEX SURFACES”

FOURTH YEAR B. TECH PROJECT REPORT

Submitted To K.B.C. North Maharashtra University, Jalgaon in Partial
Fulfilment of The Requirements for The Degree of Bachelor of Technology in
Mechanical Engineering

Submitted By
Pranjali Sunil Phirke 2002214
Gaurav Rajendra Nandeshwar 1901038
Neha Shivkumar Harinkhede 1901021
Divyesh Shantaram Patil 1901042
Swati Gajanan Khode 1901029

Under the Guidance of

Dr. S. B. Chikalthankar

DEPARTMENT OF MECHANICAL ENGINEERING GOVERNMENT

COLLEGE OF ENGINEERING, JALGAON
(An Autonomous Institute of Govt. Of
Maharashtra) (2022-23)

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 GOVERNMENT COLLEGE OF ENGINEERING, JALGAON
Department of Mechanical Engineering

CERTIFICATE

This is to certify that the project entitled “Machining Process Improvement of

CNC Machining of Concave and Convex Surfaces” is being submitted herewith
for the award of B. Tech. Degree is the result of the work completed by

Name PRN
Pranjali Sunil Phirke 2002214
Gaurav Rajendra Nandeshwar 1901038
Neha Shivkumar Harinkhede 1901021
Divyesh Shantaram Patil 1901042
Swati Gajanan Khode 1901029

Under my supervision and guidance within the four walls of the institute and the
same has not been submitted elsewhere for the award of degree.

Prof. Dr. S. B. Chikalthankar Prof. Dr. M. K. Sonpimpale

Guide and Course Co-ordinator H.O.D,
Mechanical Department

Dr. G. M. Malwatkar
Principal of GCoEJ Examiner
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3
 Declaration

We hereby declare that the project entitled, “Machining Process Improvement of CNC
Machining of Concave and Convex Surfaces” was carried out and written by us under the guidance of
Prof. Dr. S. B. Chikalthankar, Assistant Professor, Department of Mechanical Engineering, Govt.
College of Engineering, Jalgaon.
This work has not been previously formed the basis for the award of any degree or diploma or
certificate nor has been submitted elsewhere for the award of any degree.

Place: Jalgaon
Date:

Pranjali Sunil Phirke (2002214)

Gaurav Rajendra Nandeshwar (1901038)
Neha Shivkumar Harinkhede (1901021)
Divyesh Shantaram Patil (1901042)
Swati Gajanan Khode (1901029)

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 Acknowledgement

Success is never achieved single-handed. Apart from our humble efforts, this seminar is
an outcome of the help, cooperation, and guidance from various corners. We would like to add a
few heartfelt words for the people who were part of this project in numerous ways and the people
who gave unending support right from the stage of project ideas. It gives us great pleasure in
presenting the report of our project.

We take this opportunity to express our sense of gratitude to our guide Prof. Dr. S. B.
Chikalthankar, Head of Department Prof. Dr. M. K. Sonpimpale, Department of Mechanical
Engineering, Government College of Engineering, Jalgaon for his valuable guidance and
inspiration. In spite of her busy schedule, He devoted hirself and took a keen and personal interest
in giving us constant encouragement and timely suggestions.

Also, we would like to thank our honorable Principal Dr. D. G. Malwatkar for giving us
an opportunity to present this project report.

Finally, we take the opportunity to convey sincere thanks to all our friends and staff
members who contributed to letting us bring out our project report as it appears. Last but not least
the backbone of our success and confidence lies solely in the blessing of our Parents. With deep
reverences!

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 Abstract

This project focuses on the determination of optimal cutting-parameter values and tool-path
strategies for ball-end milling of EN X40CrMoV5-1 tool steel. The study employs the Taguchi
method to investigate the effects of cutting speed, feed rate, step over, and tool-path strategies
on tool acceleration. Additionally, a response-surface methodology (RSM) is utilized to develop
a model for tool acceleration as a function of cutting parameters. The experiments involve the
use of three coated cutters and measurements of tool acceleration along with orthogonal arrays.

The findings of the project indicate that the step over parameter has the most significant
influence on tool acceleration, as revealed by both the Taguchi and response-surface statistical
analyses. Confirmation experiments under optimal conditions demonstrate that measured tool-
acceleration values for convex inclined surfaces are smaller than calculated values, while for
concave inclined surfaces, measured values are larger. However, the absolute difference
between measured and calculated values remains within a range of 3.57% for both surface types.

Furthermore, the study reveals that tool acceleration is lower when machining convex inclined
surfaces compared to concave inclined surfaces, primarily due to efficient chip removal. The
tool-path style also affects tool acceleration, with the contouring tool-path style resulting in
smaller tool-acceleration values than the ramping tool-path style. This suggests that movements
parallel to the surface axis are more effective in chip removal.

The effectiveness of the response-surface methodology is demonstrated in identifying and

developing significant relationships between cutting parameters. The derived tool-acceleration
prediction model exhibits high correlation coefficients, highlighting its applicability for future
studies. Moreover, the optimized combination of cutting parameters for all surface types
involves the largest cutting velocity, the smallest step over, and an appropriate feed rate.

In conclusion, this project emphasizes the importance of the step over parameter, the distinctions
between convex and concave inclined surfaces, the impact of tool-path style, and the
effectiveness of the response-surface methodology. The findings provide valuable insights for
optimizing cutting parameters and tool-path strategies in ball-end milling processes.

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 Table of Contents

Sr. No. Title Page no.

1 Title Page 1
2 Certificate 2
3 Internship Certificate 3
4 Declaration 4
5 Acknowledgement 5
6 Abstract 6
7 Table of Contents 7
8 List of Figures 8
9 List of Tables 9
10 Chapter 1: Introduction 10-16
11 Chapter 2: Literature Survey 17-18
12 Chapter 3: Scope of the Project 19
13 Chapter 4: Justification 20-23
14 Chapter 5: Methodology 24-25
15 Chapter 6: Results and Applications 26-32
16 Chapter 7: Analysis 33-40
17 Chapter 8: Future Scope 41-42
18 Chapter 9: Conclusion 43-44
19 Chapter 10: References 45-46

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 List of Figures

Sr. No. Figure Page no.

1 Inclined surfaces and related cutter path styles: CUM-1 (upward 12
step over), CDM-1 (upward step over), CUM-2 (downward step
over), CDM-2 (downward step over), RUM-1 (left step over).
RDM-1 (left step over), RUM-2 (right step over). RDM-2 (right
step over)
2 Experimental set-up 21
3 Tool Acceleration Data 22
4 S/N ratios for milling a TiC-coated convex inclined surface 27
5 S/N ratios for milling a TiC-coated concave inclined surface 27
6 S/N ratios for milling a TiN-coated convex inclined surface 28
7 S/N ratios for milling a TiN-coated concave inclined surface 28
8 S/N ratios for milling convex inclined surfaces with a TiAlN- 29
coated cutter
9 S/N ratios for milling a TiAlN-coated concave inclined surface 29
10 Response-optimization plot for the tool-acceleration- parameter 40
components for the convex surface and TiC coating

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 List of Tables

Sr. No. Figure Page no.

1 Assignment of the levels to factors 15
2 Measure Values of Tool Acceleration 22
3 ANOVA of the tool acceleration for inclined surface types 31
4 Calculated values for convex and concave inclined surfaces 34
5 Comparison between confirmatory-test results and calculated 35
values for convex and concave inclined surfaces
6 CI values 37
7 First order-model coefficients and correlation coefficients 38
8 Polynomial-regression coefficients and correlation coefficients 38
9 Response optimization for tool-acceleration-parameter 39
components

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 Chapter 1 : Introduction

In modern manufacturing, machining is a crucial method that is continuously updated and

remains highly relevant. When machining inclined surfaces, achieving tight tolerances is
typically required for finishing and semi-finishing processes. These tasks are often accomplished
using indexable insert ball-end mills. However, high cutting speeds and rates of metal removal
can lead to excessive and irregular vibrations in cutting tools, especially during hard machining.
These vibrations can result in tool breakage, compromising process stability and quality.
Therefore, it is essential to generate optimal cutting parameters to enhance productivity in
manufacturing complex geometries and achieve desired tolerance values.

Research in this field commonly focuses on two main areas: 1) studying the effect of
cutting parameters and strategies in plain-surface milling, and 2) conducting analytical tool-
acceleration calculations and measurements for end-milling and turning operations. Various
studies have been conducted to optimize cutting parameters for turning operations, improve the
accuracy of hole diameter during dry drilling, analyze the effects of tool-path strategies on
surface roughness in pocket-milling operations, and optimize tool-geometry parameters for
turning operations.

Furthermore, investigations have been carried out to understand the correlation between
surface roughness, tool wear, and tool vibration in milling processes, specifically when working
with hardened steel and long slender tools. The influence of tool-tip vibration on surface
roughness and its measurement in ultra-precision diamond turning has also been studied.
Additionally, researchers have worked on predicting surface roughness based on cutting
parameters and tool vibrations in turning operations and examining the relationship between
vibration and tool wear during end milling.

While previous studies have focused on determining appropriate parameters for

machining flat and inclined surfaces, there is a lack of comprehensive research on the combined
effect of cutting parameters and tool-path styles on tool acceleration in machining convex and
concave surfaces using ball-end mills. This study aims to address this gap by investigating the
impact of cutting parameters and tool-path styles on tool acceleration. The goal is to minimize
tool acceleration values and control undesirable machining outcomes, such as poor surface
quality and errors.

1.1 Basic Geometric Model

The basic geometric model in this project focuses on the manufacturing process of a part from
a solid block of material through material removal. The primary objective is to achieve a high-
quality surface finish by eliminating the staircase effects that result from the initial major
material removal phase.
In ball end milling, the tool geometry plays a crucial role in achieving the desired machining
results. The tool geometry refers to the specific design and characteristics of the ball-end milling
cutter used in the process. Here are some key aspects of tool geometry in ball end milling:

1. Cutter Diameter: The diameter of the ball-end milling cutter determines the size of the cut and
the surface finish. It is typically specified in millimeters or inches and can range from a few
millimeters to several centimeters.

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 2. Flute Design: Ball-end milling cutters usually have multiple flutes that are responsible for
chip evacuation and cutting efficiency. The flute design can vary, including straight flutes, spiral
flutes, or a combination of both, depending on the application requirements.

3. Helix Angle: The helix angle refers to the angle between the cutting edge and the axis of the
tool. In ball end milling, a helix angle is commonly used to improve tool stability, chip
evacuation, and surface finish. It can range from 0 degrees (straight flute) to a higher value
(helical flute).

4. Corner Radius: Ball-end milling cutters have a curved cutting edge, which is known as the
corner radius. The corner radius determines the shape of the machined surface and affects the
tool's ability to access tight corners or contours. It is usually specified as a fraction of the cutter
diameter.

5. Coating: Many ball-end milling cutters are coated with a thin layer of material to enhance
their performance and tool life. Common coating materials include titanium nitride (TiN),
titanium carbonitride (TiCN), and aluminum titanium nitride (AlTiN). The coating can provide
increased hardness, wear resistance, and reduced friction.

6. Shank Design: The shank of the ball-end milling cutter is the portion that connects to the tool
holder. It is designed to fit into specific tool holders and machine spindles, ensuring secure
clamping and alignment during machining operations.

These are some of the important aspects of tool geometry in ball end milling. The specific tool
geometry chosen depends on the machining requirements, material being machined, desired
surface finish, and other factors. Selecting the appropriate tool geometry is essential for
achieving accurate and efficient machining results.

In the context of finishing, it is assumed that most of the material has already been removed,
leaving behind the staircases on the surface. The goal is to remove these staircases and approach
an ideal target surface 𝑆, which is assumed to be smooth. The target surface 𝑆 can be represented
as a spline surface or, alternatively, as a triangle mesh. However, to enhance smoothness, local
spline approximations can be computed if the target surface is initially represented by a triangle
mesh.

By addressing the staircase effects and striving for a smooth target surface, the project aims to
achieve a high-quality surface finish in the manufacturing process.

1.2 Cutting Tool:

The cutting tool used in the project is a complex object, as depicted in Figure 2. When the cutting
tool rotates rapidly about its axis 𝐴, it generates a solid rotational shape called T. The profile of
the cutting tool is typically composed of straight lines and circles, which is true for most available
tools in practice. The active part of the profile, designed for cutting purposes, can either be a
circle or a straight-line segment.

Overall, the cutting tool used in the project comprises various profiles, including circles, straight

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lines, and developable surfaces, to achieve specific machining objectives and adapt to different
surface curvatures.

1.3 Tool Path Strategies

In the experimental studies conducted, two tool-path styles, namely contouring and ramping, are
utilized to create inclined surfaces. These tool-path styles are established based on the up-milling
and down-milling strategies, which involve specific movements of ramping and contouring.
Ramping and contouring are essential choices for implementing these milling strategies.

In the ramping tool-path style, the cutter scans the inclined surface by following lines parallel to
the surface radius. On the other hand, in the contouring tool-path style, the cutter scans the
inclined surface by following lines perpendicular to the surface radius. Throughout the study, the
step-over values remain constant for both tool-path styles.

Figure 1: Inclined surfaces and related cutter path styles: CUM-1 (upward step over), CDM-1
(upward step over), CUM-2 (downward step over), CDM-2 (downward step over), RUM-1 (left
step over). RDM-1 (left step over), RUM-2 (right step over). RDM-2 (right step over)

After each machining step, the cutter moves sideways to a position where it returns to the starting
level of that step before proceeding to the next step. This movement pattern ensures proper tool
positioning. Four tool-path styles were generated and studied: contouring up milling (CUM),
contouring down milling (CDM), ramping up milling (RUM), and ramping down milling (RDM).

Contouring Up Milling (CUM) is a tool path strategy used in milling operations where the cutter
moves along the contour of the workpiece in an upward direction. This strategy is typically
employed when machining concave surfaces.
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In CUM, the cutter starts from the outer edge of the workpiece and progressively moves towards
the inner part of the surface, following the contour. The tool removes material from the outside
to the inside of the concave surface, resulting in the desired shape and finish.

This tool path strategy offers several advantages. Firstly, it allows for effective chip evacuation
as the chips are directed away from the machined surface. It also provides better stability and
reduced cutting forces compared to other strategies. CUM ensures a more gradual engagement
with the material, minimizing the risk of tool breakage or excessive vibration.

However, there are some considerations when using CUM. The cutter must be properly selected
to ensure access to the contour without interference from the workpiece. Additionally, the
direction and orientation of the tool path should be carefully planned to achieve the desired
surface finish and dimensional accuracy.

Overall, Contouring Up Milling is a commonly employed strategy for machining concave

surfaces, providing efficient material removal and favorable cutting conditions.

Contouring Down Milling (CDM) is a tool path strategy used in milling operations where the
cutter moves along the contour of the workpiece in a downward direction. This strategy is
typically employed when machining convex surfaces.

In CDM, the cutter starts from the inner part of the workpiece and gradually moves towards the
outer edge, following the contour. The tool removes material from the inside to the outside of the
convex surface, shaping it according to the desired form.

There are several advantages to using CDM. Firstly, it provides better tool accessibility to the
contour, especially in cases where the workpiece has complex geometries. CDM also helps in
achieving a smoother surface finish due to the continuous engagement of the cutter with the
material.

However, CDM also has some considerations. It requires careful planning and consideration of
the tool path to ensure that the cutter does not encounter any interference from the workpiece.
Additionally, since the cutter engages with the material in a more aggressive manner compared
to other strategies, it may result in higher cutting forces and increased tool wear.

Overall, Contouring Down Milling is a widely used strategy for machining convex surfaces,
offering good accessibility and the potential for achieving smooth surface finishes. Proper tool
selection and careful planning of the tool path are important for successful implementation.
Ramping Up Milling (RUM) is a tool path strategy used in milling operations where the cutter
moves along a ramped path in an upward direction. This strategy is typically employed when
machining concave surfaces.

In RUM, the cutter starts from a lower position and gradually moves upwards along a ramped
path until it reaches the desired contour of the workpiece. The ramped path allows for gradual
engagement with the material, reducing the sudden impact and potential for tool damage.

The main advantage of using RUM is that it provides better tool access and avoids sudden
changes in cutting forces. By gradually ramping up the cutter, the tool can smoothly engage with
the material, reducing the chances of chatter or vibrations. This strategy also helps in achieving
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a better surface finish due to controlled material removal.
However, there are some considerations when using RUM. The ramping path needs to be
carefully planned to avoid any collisions or interference with the workpiece or other features. The
tool's cutting-edge engagement should be properly controlled to prevent excessive material
removal or tool overload.

Overall, Ramping Up Milling is a preferred strategy for machining concave surfaces, offering
controlled engagement and improved surface finish. Careful planning and programming of the
ramped tool path are necessary for successful implementation.

Ramping Down Milling (RDM) is a tool path strategy used in milling operations where the cutter
moves along a ramped path in a downward direction. This strategy is typically employed when
machining convex surfaces.

In RDM, the cutter starts from a higher position and gradually moves downwards along a ramped
path until it reaches the desired contour of the workpiece. Like Ramping Up Milling (RUM), the
ramped path in RDM allows for gradual engagement with the material, reducing the sudden
impact and potential for tool damage.

The main advantage of using RDM is that it provides better tool access and avoids sudden
changes in cutting forces, like RUM. By gradually ramping down the cutter, the tool can smoothly
engage with the material, reducing the chances of chatter or vibrations. This strategy also helps
in achieving a better surface finish due to controlled material removal.

However, as with RUM, there are considerations when using RDM. The ramping path needs to
be carefully planned to avoid any collisions or interference with the workpiece or other features.
The tool's cutting-edge engagement should be properly controlled to prevent excessive material
removal or tool overload.

In summary, Ramping Down Milling is a tool path strategy suitable for machining convex
surfaces. It offers controlled engagement, improved surface finish, and reduced tool wear. Proper
planning and programming of the ramped tool path are essential for successful implementation.

Various parameters are used to describe the experimental conditions, including the form radius
of the workpiece (R), milling position angle (Ѳ), nominal depth of cut (ap), step over (fp), and
spindle speed (S).

By employing different tool-path styles and considering these parameters, the experimental study
aims to investigate their impact on the machining process and the resulting surface characteristics.

In the project, three variable parameters were considered for semi-finishing operations in addition
to the defined cutter path styles. These parameters were the cutting velocity (Vc), feed rate (Vf),
and cutting step over (fp). The values for cutting velocity and feed rate were obtained from the
reference catalogues provided by the tool manufacturer, specifically the Sandvik Company.

To determine the appropriate values for the cutting tool, a series of experiments were conducted
for each tool coating based on the reference values. The step-over value, which directly affects
the tracks left on the surface by the cutter, the load on the cutter, and the processing time, was set
at 5% of the tool diameter. This value was chosen as the lower level for the step-over parameter.
The depth of cut was kept constant at 0.3 mm throughout the experiments.
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For the experimental design, an orthogonal array of L'16 was selected. This allowed for a
systematic variation of the cutting parameters. Four different levels were defined for each cutting
parameter, providing a range of values to be tested and analyzed in the study.

Table 1 : Assignment of the levels to factors

Table 1: In the mentioned study, three variable parameters were considered for semi-finishing
operations in ball-end milling: cutting velocity (Vc), feed rate (Vf), and cutting step over (fp). The
cutting-velocity and feed-rate values were obtained from the reference catalogues of the tool
manufacturer (Sandvik Company). These values provide a starting point for selecting suitable
cutting conditions.

To determine the appropriate cutting-tool values, a series of experiments were conducted for each
tool coating based on the reference values. This experimental approach helps identify the optimal
cutting parameters for the specific tool coating being used.

The cutting-tool step-over values play a significant role in the machining process. They directly
influence the tracks or paths created on the machined surface by the cutter, as well as the load
imposed on the cutter and the overall processing time. In this study, the step-over value was set
to 5% of the tool diameter, and this value was considered the lower level of fp. The step-over
value determines the distance the cutter moves sideways between successive passes.

The depth of cut was chosen as a constant value of 0.3 mm for all the experiments, meaning the
tool penetrates the workpiece to a depth of 0.3 mm during each pass.

To design the experiments systematically, an orthogonal array of L'16 was chosen. An orthogonal
array helps ensure efficient and balanced experimental design by providing a set of predefined
combinations of the independent variables (cutting parameters) at different levels. In this case,
four different levels were defined for each cutting parameter, allowing for a comprehensive
exploration of the parameter space.

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By conducting experiments using the defined orthogonal array and varying the cutting parameters
at different levels, the researchers were able to collect data on the tool acceleration and analyze
the effects of the cutting parameters on the machining process.

Overall, this approach enables the identification of optimal cutting conditions for semi-finishing
operations in ball-end milling, considering factors such as cutting velocity, feed rate, and cutting
step over, to achieve desired machining outcomes with respect to surface quality, tool load, and
processing time.

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 Chapter 2: Literature Survey

1. Title: "Investigation of Tool Path Strategies for 5-Axis CNC Machining of Complex
Surfaces"
Authors: Zhang, Y., Zhao, J., & Chen, X.
Published in: Procedia CIRP, 2016
Summary: This study reviews various tool path strategies for 5-axis CNC machining of
complex surfaces, including concave and convex surfaces. It explores the effects of
different strategies on machining performance, surface quality, and tool acceleration.

2. Title: "Optimization of CNC Machining Parameters for Improved Surface Quality"

Authors: Singh, H., Kapoor, S., & Kaur, S.
Published in: International Journal of Mechanical Engineering and Robotics Research,
2018
Summary: This paper presents a literature survey on optimization techniques for CNC
machining parameters to enhance surface quality, including concave and convex surfaces.
It discusses the influence of cutting parameters and tool path strategies on surface
roughness, dimensional accuracy, and tool acceleration.

3. Title: "Tool Path Strategies for CNC Machining of Freeform Surfaces"

Authors: Chen, X., Zhang, Y., & Hu, L.
Published in: The International Journal of Advanced Manufacturing Technology, 2017
Summary: This literature survey examines different tool path strategies for CNC
machining of freeform surfaces, including concave and convex surfaces. It evaluates their
impact on machining efficiency, surface integrity, and tool acceleration, providing
insights for process improvement.

4. Title: "Optimization of CNC Machining Parameters Using Response Surface

Methodology"
Authors: Srinivasan, G., & Sivaraman, V.
Published in: International Journal of Precision Engineering and Manufacturing, 2016
Summary: This study presents a literature survey on the optimization of CNC machining
parameters using response surface methodology. It explores the optimization techniques
employed for concave and convex surface machining, focusing on parameters such as
cutting speed, feed rate, and step over to enhance surface quality and reduce tool
acceleration.

5. Title: "Machining Process Optimization for CNC Milling of Complex Surfaces"

Authors: Lee, Y., & Shin, Y.
Published in: Journal of Mechanical Science and Technology, 2019
Summary: This paper provides a literature survey on machining process optimization for
CNC milling of complex surfaces, including concave and convex surfaces. It discusses
the application of optimization techniques such as Taguchi method and response surface
methodology to improve machining performance, dimensional accuracy, and tool
acceleration.

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6. Title: "Tool Path Generation and Machining Strategies for CNC Machining of Curved
Surfaces"
Authors: Liu, L., & Ding, Y.
Published in: The International Journal of Advanced Manufacturing Technology, 2017
Summary: This literature survey focuses on tool path generation and machining strategies
for CNC machining of curved surfaces, including concave and convex surfaces. It
discusses the challenges associated with tool path generation, surface finish, and tool
acceleration, along with approaches to optimize the machining process.

7. Title: "Optimization of Machining Parameters for Improved Surface Quality in CNC

Milling"
Authors: Das, S., & Panda, S.
Published in: Journal of the Brazilian Society of Mechanical Sciences and Engineering,
2019
Summary: This survey reviews the optimization of machining parameters for improved
surface quality in CNC milling operations, considering concave and convex surfaces. It
discusses the influence of cutting parameters on surface roughness, tool acceleration, and
machining efficiency, providing insights into process optimization strategies.

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 Chapter 3: Scope of the Project

1. The scope of a project focused on machining process improvement of CNC machining of

concave and convex surfaces can include various aspects and objectives. Here are some
potential scopes for such a project:

2. Optimization of Cutting Parameters: The project can aim to optimize the cutting
parameters, including cutting speed, feed rate, step over, and tool path strategies, to
achieve improved surface quality, dimensional accuracy, and tool acceleration for
concave and convex surfaces.

3. Tool Selection and Geometry: The project can explore the selection of appropriate cutting
tools and their geometries for machining concave and convex surfaces. It can involve
evaluating different tool designs, coatings, and materials to enhance tool life, cutting
performance, and minimize tool wear and vibration.

4. Surface Finish Enhancement: The project can focus on improving the surface finish of
concave and convex surfaces through the investigation of machining techniques, tool
paths, and surface treatments. It can explore methods such as high-speed machining,
vibration-assisted machining, and post-machining surface treatments to achieve desired
surface roughness and texture.

5. Process Monitoring and Control: The project can involve the development and
implementation of process monitoring and control techniques to ensure consistent and
reliable machining of concave and convex surfaces. This may include real-time
monitoring of cutting forces, tool vibrations, and temperature to detect anomalies and
optimize the machining process accordingly.

6. Modeling and Simulation: The project can utilize modeling and simulation techniques to
analyze the machining process of concave and convex surfaces. It can involve developing
mathematical models, finite element analysis (FEA), or computer-aided machining
simulations to predict tool acceleration, surface quality, and optimize cutting parameters.

7. Tool Path Optimization: The project can focus on optimizing the tool path strategies for
machining concave and convex surfaces. It can investigate the effects of different tool
path patterns, such as zig-zag, trochoidal, or adaptive tool paths, on surface quality, chip
evacuation, and tool acceleration.

8. Sustainability and Cost Optimization: The project can explore sustainable machining
practices for concave and convex surfaces, aiming to minimize energy consumption,
reduce material waste, and optimize tool life. It can involve evaluating the environmental
impact, cost-effectiveness, and resource efficiency of different machining approaches and
process parameters.

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 Chapter 4: Justification

2.1 EXPERIMENTAL PART

In the project, three variable parameters were considered for semi-finishing operations in addition
to the defined cutter path styles. These parameters were the cutting velocity (Vc), feed rate (Vf),
and cutting step over (fp). The values for cutting velocity and feed rate were obtained from the
reference catalogues provided by the tool manufacturer, specifically the Sandvik Company.

To determine the appropriate values for the cutting tool, a series of experiments were conducted
for each tool coating based on the reference values. The step-over value, which directly affects
the tracks left on the surface by the cutter, the load on the cutter, and the processing time, was set
at 5% of the tool diameter. This value was chosen as the lower level for the step-over parameter.
The depth of cut was kept constant at 0.3 mm throughout the experiments.

For the experimental design, an orthogonal array of L'16 was selected. This allowed for a
systematic variation of the cutting parameters. Four different levels were defined for each cutting
parameter, providing a range of values to be tested and analyzed in the study.

In the study, the EN X40CrMoV5-1 hot-work tool steel was selected as the material of interest.
This particular steel is widely used in tool-making processes due to its favorable characteristics,
including high durability, high thermal conductivity, high machinability, and high cracking
resistance.

For the experiments, the researchers machined experimental samples with dimensions of (40 ×
30) mm on a larger (220 × 135 × 50) mm block. An indexable cutter body with an Ø16 mm
cylindrical shank, specifically the CoroMill R216-16A20-045, was used. This cutter body
featured a two-fluted 30°-helix-angle end mill. The ball-end inserts used were coated with TiC,
TiN, and TiAlN, each with a 3-μm coating thickness (R216-16 03 M-M H13A).

Semi-finishing operations were conducted in the experiments, and no coolant was used during
the machining process. The experiments were performed on a vertical machining center,
specifically the John Ford VMC 550, equipped with a 12-kW engine and a rotational speed of
12,000 min–1. The experimental setup is depicted in Figure 2, which is referenced in the project.

During the cutting process, the acceleration of the vibration signals was measured using a
piezoelectric accelerometer called VibroTest 60. The measurement was carried out following the
ISO 2954 standard. The accelerometer was mounted on the workpiece using a magnetization
feature, allowing for precise monitoring of the vibration signals generated during cutting.

20
 Figure 2: Experimental set-up

2.2 Tool Acceleration

Tool acceleration is a phenomenon that occurs during machining operations as a result of the
interaction between the tool and the workpiece. It is influenced by factors such as the structure of
the tool and workpiece, as well as the cutting conditions employed. Each pass of the tool's cutting
teeth leaves a modulated surface on the workpiece, leading to variations in the expected chip
thickness.

Under specific cutting conditions, such as certain feed rates, depth of cut, and cutting velocities,
significant variations in chip thickness occur, causing force and displacement variations and
ultimately resulting in vibrations. These vibrations can have detrimental effects on the machining
process, including poor surface finish, increased tool wear, reduced dimensional accuracy, and
potential tool damage. To mitigate these issues, conservative cutting conditions are often chosen
to minimize the occurrence of vibrations and maintain productivity.

In the project, the values of tool acceleration were experimentally measured during the machining
of inclined surfaces. The specific results of these measurements can be found in Table 2,
providing valuable insights into the relationship between cutting parameters and tool acceleration.

21
0.7
Tool Acceleration
0.6

0.5

0.4

0.3

0.2

0.1

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

(m/s2 peak) (TiC) (m/s2 peak) (TiN) (m/s2 peak) (TiAlN)

(m/s2 peak) (TiC) (m/s2 peak) (TiN) (m/s2 peak) (TiAlN)

Figure 3 : Tool Acceleration Data

Table 2 : Measure Values of Tool Acceleration

22
The chosen experimental design for this project was an L16 (44) orthogonal array, which consists
of 16 rows corresponding to the number of experiments conducted. There were 4 factors being
investigated, each with 4 levels. The objective was to determine the optimum cutting performance
based on the tool acceleration, where a smaller-the-better quality characteristic was considered
desirable.

To evaluate the performance, a signal-to-noise (S/N) ratio was used as a metric. The S/N ratio
was defined according to Equation (1), although the equation itself was not provided in the given
information.

The S/N ratio is a statistical measure that quantifies the relationship between the signal (desired
outcome) and the noise (undesirable variations or disturbances) in a system. In the context of this
project, the S/N ratio was used to assess the tool acceleration and its variation across different
cutting parameters and levels. By analyzing the S/N ratio, researchers could identify the optimal
combination of cutting parameters that resulted in the least tool acceleration, indicating better
cutting performance.

where Yi is the observed data at the ith experiment and n is the number of experiments.

23
 Chapter 5: Methodology
5.1 Response surface methodology (RSM)

Response surface methodology (RSM) is a statistical and mathematical technique used for
optimizing and modeling the relationship between a response variable and multiple input
variables in an experimental study. It is commonly applied in engineering, manufacturing, and
scientific research to understand and optimize complex processes.

RSM involves designing and conducting a series of experiments by varying the input variables
according to a specific experimental design. The response variable of interest, such as tool
vibration, surface roughness, or process yield, is measured for each combination of input
variables. By analysing the experimental data, mathematical models are developed to describe
the relationship between the response variable and the input variables.

The models generated using RSM can be used to predict and optimize the response variable
within the range of the input variables. They provide insights into the main effects of individual
variables, as well as interactions between variables. With the help of statistical analysis
techniques, such as analysis of variance (ANOVA) and regression analysis, significant factors
and optimal settings can be identified.

RSM is advantageous as it reduces the number of experiments required compared to a full

factorial design. It allows for efficient exploration of the design space and helps in identifying the
optimal combination of input variables that lead to the desired response. This methodology has
been widely used in process optimization, parameter design, and improvement of product quality
and performance.

In the context of the project mentioned earlier, RSM was employed to develop a model for tool
acceleration as a function of the cutting parameters. By utilizing RSM, the researchers were able
to predict the tool vibration values based on the cutting parameters and tool path strategy, thereby
enabling the identification of optimal cutting conditions to minimize tool acceleration and
improve the overall machining process.

Equation (2) represents a second-order polynomial model commonly used in response surface
methodology (RSM). The model relates the responses (output variables of interest) to the
independent variables (input parameters) in a functional form.

In general, the second-order polynomial model can be expressed as:

Y = β₀ + β₁X₁ + β₂X₂ + β₃X₁² + β₄X₂² + β₅X₁X₂ + ε

where:

Y is the response variable or output of interest.

X₁, X₂, ..., Xₖ are the independent variables or input parameters.
β₀, β₁, β₂, β₃, β₄, β₅ are the coefficients to be estimated.
ε represents the residual or error term.
The model includes linear terms (β₁X₁, β₂X₂), quadratic terms (β₃X₁², β₄X₂²), and interaction term
(β₅X₁X₂) to capture the relationship between the responses and the input variables. The

24
coefficients β₀, β₁, β₂, β₃, β₄, β₅ are estimated using statistical techniques, such as regression
analysis.

Equation 2 can also expressed as:

By fitting the second-order polynomial model to the experimental data, the adequacy of the model
can be statistically assessed. The model can then be utilized for optimization purposes, such as
finding the optimal combination of input variables that maximizes or minimizes the response
variable.

RSM provides a systematic and efficient approach to understand the relationship between
variables, identify significant factors, and optimize process or system performance. It is widely
used in various fields to improve product quality, optimize processes, and make informed
decisions based on experimental data.

25
 Chapter 6: Results and Application
The S/N ratios (Signal-to-Noise ratios) of four factors were calculated using Equation (1). These
factors likely represent variables or parameters related to the experiment.

The purpose of calculating the S/N ratios is to determine the optimum quality with the minimum
variance. The S/N ratio measures the quality of a signal (desired effect) relative to the noise
(undesired effects or variations). In this case, the larger the S/N ratio, the better the quality and
the smaller the variation.

By calculating the S/N ratios for each factor and for different tool coatings and inclined surface
types (as shown in Figures 3 to 8), the researchers can identify the factor levels that yield the
largest S/N ratios. The factor level with the largest value is then considered the optimum level for
that factor.

In the project, the S/N ratios (signal-to-noise ratios) were calculated for the four factors (cutting velocity,
feed rate, cutting step over, and tool-path style) in relation to different tool coatings and inclined surface
types (convex and concave). The S/N ratio represents the quality characteristic of the tool acceleration,
and a higher S/N ratio indicates better performance with less variation.

By analyzing Figures 3 to 8, which present the results for milling TiC-coated, TiN-coated, and TiAlN-
coated surfaces, the optimum levels for each factor can be determined based on the largest S/N ratio. These
optimum levels correspond to the cutting conditions that yield the highest tool acceleration quality with
minimum variance.

For example, in the case of milling TiC-coated surfaces, the optimum levels were observed at A4 for
cutting velocity (100 m/min), B1 for feed rate (223 min–1), C1 for cutting step over (0.8 mm), and D4
(UMC) for the tool-path style when considering the convex inclined surface. Similarly, for the concave
inclined surface, the optimum levels were observed at A4, B1, C1, and D1 (DMR) for the respective
factors.

Similar patterns were observed for the milling of TiN-coated and TiAlN-coated surfaces, with specific
optimum levels identified for each factor and surface type. The cutting velocity, feed rate, cutting step
over, and tool-path style that yielded the highest tool acceleration quality varied depending on the surface
type and the specific coating used.

The results indicated that as the cutting velocity (Vc) increased, the tool acceleration values slightly
decreased, which aligns with the findings in previous references. This can be attributed to factors such as
deformations of the cutting tool's main cutting edge and the resulting contact length between the tool and
the workpiece. Additionally, the chip cross-sectional area generated by the cutting step over (fp) and feed
rate (Vf) had a significant influence on the tool acceleration, with higher values of fp and Vf leading to
increased tool acceleration.

Overall, the project's findings highlight the importance of selecting the appropriate cutting conditions
(cutting velocity, feed rate, cutting step over) and tool-path style to achieve optimal tool acceleration and
surface quality when milling inclined surfaces with different tool coatings.

26
Figure 4: S/N ratios for milling a TiC-coated convex inclined surface

Figure 5: S/N ratios for milling a TiC-coated concave inclined surface

27
Figure 6: S/N ratios for milling a TiN-coated convex inclined surface

Figure 7: S/N ratios for milling a TiN-coated concave inclined surface

28
Figure 8: S/N ratios for milling convex inclined surfaces with a TiAlN-coated cutter

Figure 9: S/N ratios for milling a TiAlN-coated concave inclined surface

29
Figures 3 to 8 present the results of milling experiments on different types of inclined surfaces using
various tool coatings. These figures show the S/N ratios for each factor at different levels.

From Figures 3 and 4 (milling of TiC-coated surfaces), the optimum levels for the tool acceleration (Vc),
feed rate (Vf), axial depth of cut (fp), and tool-path style can be observed. The optimal levels are as
follows:

Vc (Tool Acceleration): A4 (100 m/min)

Vf (Feed Rate): B1 (223 min^(-1))
fp (Axial Depth of Cut): C1 (0.8 mm)
Tool-Path Style: D4 (UMC) for convex inclined surfaces and D1 (DMR) for concave inclined surfaces.
Similarly, from Figures 5 and 6 (milling of TiN-coated surfaces), the optimum levels for the tool
acceleration, feed rate, axial depth of cut, and tool-path style are:

Vc (Tool Acceleration): A4 (130 m/min)

Vf (Feed Rate): B1 (318 min^(-1))
fp (Axial Depth of Cut): C1 (0.8 mm)
Tool-Path Style: D1 (DMR) for both convex and concave inclined surfaces.
Finally, from Figures 7 and 8 (milling of TiAlN-coated surfaces), the optimum levels for the tool
acceleration, feed rate, axial depth of cut, and tool-path style are:

Vc (Tool Acceleration): A4 (140 m/min)

Vf (Feed Rate): B1 (358 mm/rev)
fp (Axial Depth of Cut): C1 (0.8 mm)
Tool-Path Style: D1 (DMR) for both convex and concave inclined surfaces.
These optimal levels were determined based on the largest S/N ratios, indicating the highest quality and
minimum variance for each factor and coating type in the milling process.

30
Source of variance DOF, v SS Variance, V F ratio (𝛼=5p PCR (%)
%)
Convex inclined surface (TiC)
Cutting velocity, Vc (m/min) 3 0.0050203 0.0016734 5.92 0.049 11.70
Feed rate, Vf (m/rev) 3 0.0092032 0.0030677 10.85 0.041 21.50
Step over, fp (mm) 3 0.0255268 0.0085089 30.09 0.010 59.60
Tool-path style 3 0.0022432 0.0007477 2.64 0.223 5.20
Error, e 3 0.0008483 0.0002828 2.00
Total 15 0.0428417 100.00
Concave inclined surface (TiC)
Cutting velocity, Vc (m/min) 3 26.015 8.672 1.84 0.050 13.63
Feed rate, Vf (m/rev) 3 21.613 7.204 1.53 0.048 11.32
Step over, fp (mm) 3 120.608 40.203 8.52 0.036 63.19
Tool-path style 3 8.455 2.818 0.6 0.659 4.43
Error, e 3 14.148 4.716 7.41
Total 15 190.839 100.00
Convex inclined surface (TiN)
Cutting velocity, Vc (m/min) 3 0.002192 0.0007307 3.54 0.490 10.99
Feed rate, Vf (m/rev) 3 0.002838 0.0009461 4.58 0.042 14.23
Step over, fp (mm) 3 0.014166 0.0047221 22.88 0.014 71.03
Tool-path style 3 0.000126 0.0000419 0.2 0.888 0.63
Error, e 3 0.000619 0.0002064 3.1
Total 15 0.019941 100.00
Concave inclined surface (TiN)
Cutting velocity, Vc (m/min) 3 0.006494 0.002165 0.44 0.048 3.22
Feed rate, Vf (m/rev) 3 0.04115 0.013717 2.81 0.040 20.42
Step over, fp (mm) 3 0.133717 0.044572 9.14 0.021 66.37
Tool-path style 3 0.005465 0.001822 0.37 0.780 2.71
Error, e 3 0.014633 0.004878 7.26
Total 15 0.20146 100.00
Convex inclined surface (TiAlN)
Cutting velocity, Vc (m/min) 3 0.005747 0.001916 1.42 0.050 15.07
Feed rate, Vf (m/rev) 3 0.009267 0.003089 2.29 0.045 24.3
Step over, fp (mm) 3 0.017734 0.005911 4.37 0.028 46.51
Tool-path style 3 0.00132 0.00044 0.33 0.809 3.46
Error, e 3 0.004055 0.001352 10.63
Total 15 0.038123 100.00
Concave inclined surface (TiAlN)
Cutting velocity, Vc (m/min) 3 0.005838 0.001946 5.53 0.047 6.37
Feed rate, Vf (m/rev) 3 0.020738 0.006913 19.63 0.018 22.63
Step over, fp (mm) 3 0.059669 0.01989 56.49 0.004 65.12
Tool-path style 3 0.004318 0.001439 4.09 0.139 4.71
Error, e 3 0.001056 0.000352 1.15
Total 15 0.091619 100.00

Table 3: ANOVA of the tool acceleration for inclined surface types

31
In the machining of inclined surfaces, as seen in Figures 3 to 8, the tool-acceleration values
decreased slightly with an increase of Vc, in line with the data from references4,18,21. The
literature emphasizes that a slight increase in Vc is caused by the following reasons: deformations
of the main cutting edge of the cutting tool increase with a decrease in Vc, and this causes an
increase in the contact length between the cutting tool and the workpiece. The longer contact
length between the cutting tool and the workpiece increases the friction
force on the cutting-tool rake face and this leads to an increase in the tool acceleration depending
on the cutting forces.4,21 The chip cross-sectional area generated by fp and Vf is the most
influential factor in determining the tool acceleration. As the fp and Vf values increase, the tool
acceleration increases as seen in Figures 3 to 8.

32
 Chapter 7: Analysis

7.1 Analysis of variance

In the project, an analysis of variance (ANOVA) was conducted to determine which cutting
parameters had a statistically significant impact on the tool acceleration. The calculated S/N ratio
under the optimum machining conditions was compared to the arithmetic mean of the S/N ratio
of the studied surface form. The p-values obtained from the ANOVA analysis indicate the
significance of the differences between the measured values.

Table 3 presents the results of the ANOVA analysis for all the cutting parameters and tool-path
styles at a significance level of 95%. The significance of the differences between the levels is
indicated by the p-values. A p-value below the significance level indicates that the corresponding
cutting parameter or tool-path style has a significant effect on the tool acceleration.

Table 4 provides the response values of the tool acceleration for different types of coated cutters
(TiC, TiN, and TiAlN) when machining convex and concave inclined surfaces. It identifies the
most significant cutting parameters for each case based on their p-values.

For example, when using the TiC-coated cutter, the cutting parameters fp (cutting step over), Vf
(feed rate), and Vc (cutting velocity) were found to be statistically significant for both convex
and concave inclined surfaces. Their respective p-values indicate the level of significance. Similar
trends were observed for the TiN-coated and TiAlN-coated cutters, with fp, Vf, and Vc being the
most significant control factors for both surface types.

It is noteworthy that in all cases, the cutting step over (fp) was identified as a more significant
parameter compared to the feed rate (Vf). This suggests that the choice of cutting step over has a
stronger influence on the tool acceleration and overall machining performance.

Overall, the ANOVA analysis helps identify the key cutting parameters that significantly affect
the tool acceleration when machining different types of inclined surfaces with various coated
cutters. This information is valuable for optimizing the cutting conditions and achieving
improved tool performance and surface quality.

7.2 Determination of the optimum machining parameters and confirmation experiments

The given information provides the optimal parameter combinations for machining convex and
concave inclined surfaces using different coated cutters. The parameters are denoted by their
respective levels: A4, B1, C1, and D1-D4.

For machining convex inclined surfaces:

- TiC-coated cutter: The optimal parameter combination is A4B1C1D1.
- TiN-coated cutter: The optimal parameter combination is A4B1C1D1.
- TiAlN-coated cutter: The optimal parameter combination is A4B1C1D3.

For machining concave inclined surfaces:

- TiC-coated cutter: The optimal parameter combination is A4B1C1D4.
- TiN-coated cutter: The optimal parameter combination is A4B1C1D1.
- TiAlN-coated cutter: The optimal parameter combination is A4B1C1D1.
33
The results are obtained by considering the parameters' levels and their effects on the tool
acceleration. The specific equations (Equations 3 and 4) mentioned in the text are not provided,
but they likely involve predicting and calculating the tool acceleration based on the given
parameter combinations.

To fully understand the prediction methodology and calculate the results in advance, it is
necessary to refer to the original research or additional information that includes Equations 3 and
4. These equations likely involve statistical models or algorithms that estimate the tool
acceleration based on the chosen parameters.

It is important to note that the given text refers to Table 4, which contains the results of the
prediction. Reviewing Table 4 and understanding the calculations and statistical analysis used
will provide more insights into the predictive modeling process.

Table 4: Calculated values for convex and concave inclined surfaces

Convex inclinedsurface Concave inclinedsurface
Coatings

Acccal Acccal
5cal(dB) (m/s2 peak) 5cal(dB) (m/s2 peak)

TiC 20.727 0.092 20.915 0.090

TiN 19,337 0.108 13.722 0.206

TiAlN 14.991 0.178 14.379 0.191

The purpose of these experiments was to ensure that the optimal control factor settings identified
for each coating type would yield consistent results.

To eliminate any potential interference from worn cutting tools, new cutters were used for each
coating type. This approach ensured that the effects observed during the tests were solely due to
the coatings and not influenced by the condition of the cutting tools.

34
 The results of the experiments are presented in Table 5. The table includes two test trials for each
coating type. For each trial, two key parameters are reported: acceleration values (Accmea) and
S/N ratios (Ƞmea).

The acceleration values (Accmea) represent the measured acceleration during the experiments.
This parameter is likely relevant to assessing the performance and effectiveness of the coatings.
Higher acceleration values may indicate enhanced cutting efficiency or other desirable
characteristics.

The S/N ratios (Ƞmea) represent the signal-to-noise ratios calculated based on the measured data.
These ratios are often used in experimental design and analysis to evaluate the variability of the
results. A higher S/N ratio suggests a more desirable and consistent performance of the coating.

By conducting confirmation experiments and analyzing the results, researchers can validate that
the optimal control factor settings identified for each coating type consistently yield the desired
performance. This information is valuable for decision-making and further optimizing the coating
processes for cutter production.

Table 5: Comparison between confirmatory-test results and calculated values for convex and
concave inclined surfaces

Exp. Acceleration Accelerationmea Acceleration Absolute differences

No. (m/s2 peak) (m/s2 peak) (Ƞmea, dB) (%)*
Convex inclined surface
TiC 1 0.086 0.090 20.906 0.2
2 0.094
TiN 1 0.091 0.101 19.871 0.7
2 0.111
TiAlN 1 0.153 0.172 15.236 0.6
2 0.191
Concave inclined surface
TiC 1 0.101 0.103 19.741 1.3
2 0.105
TiN 1 0.202 0.203 13.849 0.3
2 0.204
TiAlN 1 0.179 0.188 14.506 0.3
2 0.197

* Acccal Accmea 100

Accmea

7.3 Confidence interval

1. Estimating the Mean: Estimating the mean refers to calculating a point estimate based on the
average of the results obtained from an experiment. However, this point estimate alone does not
provide a complete understanding of the true average value. It is crucial to consider the
uncertainty associated with the estimate.

35
2. Confidence Interval (CI): A confidence interval is a statistical measure that provides a range
of values within which the true average is expected to fall with a certain level of confidence. It
includes both the maximum and minimum values that define the range. By calculating a
confidence interval, we can have a more comprehensive understanding of the variability and
uncertainty around the estimated mean.

3. Verification of Quality Characteristics: Confidence intervals are used to verify the quality
characteristics of confirmation experiments. By setting a desired level of confidence (e.g., 95%),
the confidence interval allows us to determine whether the true average falls within the calculated
range. If the confidence interval includes the desired target value, it suggests that the quality
characteristics meet the required standards.

4. Calculation of Confidence Interval: The passage mentions the calculation of a confidence

interval using specific equations (Equations 5 and 6) and provides the resulting confidence
interval values in Table 6. The specific equations and calculations may be context-specific and
based on the statistical methods employed in the study.

5. S/N Ratio and Confirmation Experiments: The passage also refers to the S/N ratio, which is a
measure of the signal-to-noise ratio used to assess the quality or performance characteristics. The
differences between estimated values obtained from equations (2) and (3) and the results obtained
from confirmation experiments are analysed. The smallest differences are observed at a 5%
confidence interval value, indicating that the tested surfaces and coatings meet the desired
control-factor settings and can be considered safe.

When estimating the mean based on the average of experimental results, it only provides a single
point estimate. This means that there is a 50% chance that the true average could be higher or
lower than the estimated mean. To gain a better understanding of the true average, it is important
to calculate a confidence interval (CI).

A confidence interval is a range of values within which the true average is expected to fall with
a certain level of confidence. It provides a measure of the uncertainty associated with the
estimated mean. The confidence interval is used to assess the quality characteristics of
confirmation experiments.

To calculate the confidence interval, a specific formula is used, which involves statistical values
such as the F ratio, error variance, effective number of replications, and total main factor degrees
of freedom. These values are obtained from the experimental data. The formula helps determine
the range within which the true average is likely to be.

In simpler terms, a confidence interval is like a "margin of error" around the estimated mean. It
provides a range of values that the true average is expected to be within, with a certain level of
confidence. The formula used to calculate the confidence interval takes into account various
statistical factors from the experiment. The confidence interval helps us better understand and
verify the quality of the confirmation experiments. The specific confidence interval values for
convex and concave inclined surfaces can be found in Table 6.
36
 Table 6: CI values

Type of Surface Tool acceleration (m/s2 peak)

TiC TiN TiAlN

Convex inclined surface 0.047 0.023 0.062

Concave inclined surface 2.027 0.120 0.061

The S/N ratio differences between the estimated values obtained using Equations (2) and (3), and
the results obtained with the confirmation experiments are shown in Table 5. The differences
appear to be the smallest at a confidence-interval value of 5 % given in Table 6. Therefore, both
inclined surfaces and all the coatings used are confirmed as safe, having the optimal control-
factor settings.

7.4 Prediction of the tool acceleration:

The prediction of tool acceleration was accomplished by developing a tool-acceleration

prediction model using a methodology called response surface methodology (RSM). RSM
combines statistical and mathematical techniques to develop and optimize processes. In this case,
the RSM was used to optimize the tool acceleration by creating a polynomial model of either first
order or second order, depending on the situation.

Based on the conducted machinability experiments, a mathematical model for tool acceleration
was derived using a first-order model and a quadratic polynomial. The tool acceleration model
depends on the values of Vc, Vf, and fp, which are cutting-parameter variables.

Equation (7) presents the mathematical representation of the tool acceleration model obtained
from the experiments. The equation includes the coefficients of the polynomial and first-order
model, which are essential for the prediction.

To further evaluate the quality and reliability of the model, the regression coefficients and the
correlation coefficient for the mathematical model of Ra (tool acceleration) are provided in Tables
7 and 8, respectively. These coefficients indicate the strength of the relationship between the
cutting parameters and the tool acceleration and can be used to assess the accuracy of the
prediction model.

In summary, the prediction of tool acceleration was achieved through the development of a
mathematical model using response surface methodology (RSM). The model utilizes polynomial
equations and regression coefficients derived from the machinability experiments to estimate tool
acceleration based on cutting-parameter values. The provided tables offer additional information
on the coefficients and correlation coefficient, allowing for the evaluation of the model's quality.

37
The values of the polynomial and first-order model regression coefficients and the correlation
coefficient for the mathematical model of Ra are given in Tables 7 and 8.

Table 7: First order-model coefficients and correlation coefficients

Regression coefficients
Coefficient Multiplier
Convex inclinedsurface Concave inclinedsurface

TiC TiN TiAlN TiC TiN TiAlN

k0 Sabit 0.195 0.183 0.197 0.533 0.376 0.344

k1 Vc -0.025 -0.011 -0.020 -0.099 -0.025 -0.022

k2 Vf 0.023 0.013 0.029 0.095 0.059 0.021

k3 fp 0.051 0.037 0.042 0.183 0.116 0.078

Correlation coefficients
%
89.19 88.80 86.26 85.77 83.48 83.72

Table 8: Polynomial-regression coefficients and correlation coefficients

Regression coefficients
Coeffi-cient Multi-plier Convex inclinedsurface Concave inclinedsurface

TiC TiN TiAlN TiC TiN TiAlN

k0 Sabit 0.205 0.206 0.217 0.534 0.322 0.333
k1 Vc -0.037 -0.015 -0.024 -0.166 -0.005 -0.043
k2 Vf 0.016 0.010 0.030 0.132 0.063 0.017
k3 Fp 0.045 0.030 0.025 0.181 0.060 0.037
k4 Vc × Vc -0.028 -0.020 -0.022 -0.010 0.012 -0.005
k5 Vf × Vf 0.002 -0.009 -0.018 0.023 0.055 0.000
k6 fp × fp 0.057 -0.012 0.000 -0.014 0.015 0.014
k7 Vc × Vf -0.010 -0.012 -0.029 -0.004 -0.096 -0.070
k8 Vc × fp -0.008 -0.004 0.002 0.082 0.000 -0.027
k9 Vf × fp -0.017 -0.006 -0.006 -0.125 0.031 0.000
Correlation coefficients
%
91.79 94.54 90.57 92.13 97.04 85.29

38
 The correlation coefficients obtained for the TiC, TiN, and TiAlN coatings on the convex inclined
surface were 91.79%, 94.54%, and 90.57% respectively. Similarly, for the concave inclined
surface, the correlation coefficients were 92.13%, 97.04%, and 85.29% for the TiC, TiN, and
TiAlN coatings respectively. These coefficients indicate that the generated model successfully
predicts the tool acceleration values for both the convex and concave inclined surfaces.

7.5 Optimization of the response:

The primary objective of the manufacturing experiments is to attain the desired tool acceleration
using optimal cutting parameters. In this context, response surface optimization is considered an
ideal technique for determining the tool acceleration in ball-end milling. The specific goal in this
case is to minimize the tool acceleration.

Figure 9 displays the results of the response surface optimization for the acceleration parameter
concerning the convex inclined surface and the TiC coating. This figure likely illustrates the
relationship between the cutting parameters and the tool acceleration, highlighting the optimized
region that minimizes acceleration.

Table 9 presents the optimal cutting parameters obtained for all surface types and coatings. These
parameters represent the ideal values that should be used to achieve the desired tool acceleration
for each specific surface type and coating.

In summary, the experiments aimed to achieve the desired tool acceleration by optimizing the
cutting parameters. Response surface optimization was utilized as a technique to minimize the
tool acceleration. The results of the optimization process for the convex inclined surface and TiC
coating are shown in Figure 9, while Table 9 provides the optimal cutting parameters for all
surface types and coatings.

Table 9: Response optimization for tool-acceleration-parameter components

Optimum combination Lower Target Upper Pre. Desira-

Parameter Goal respons bility
e
Vc Vf fp (mm)
(mm/min) (m/rev)
Convex surface, TiC
Acceleration (m/s2 peak) Min. 100 223 0.8 0.125 0.125 0,292 0.119 1
Convex surface, TiN
Acceleration (m/s2 peak) Min. 130 318 0.8 0.117 0.117 0.239 0.116 1
Convex surface, TiAlN
Acceleration (m/s2 peak) Min. 140 350 0.8 0.103 0.103 0.286 0.112 1
Concave surface, TiC
Acceleration (m/s2 peak) Min. 100 223 0.8 0.287 0.287 0.637 0.249 1
Concave surface, TiN
Acceleration (m/s2 peak) Min. 130 318 0.8 0.254 0.254 0.471 0.226 1
Concave surface, TiAlN
Acceleration (m/s2 peak) Min. 140 350 0.8 0.241 0.241 0.465 0.222 1

39
Figure 10: Response-optimization plot for the tool-acceleration- parameter components for
the convex surface and TiC coating

40
 Chapter 8: Future Scope
The future scopes of a project focused on machining process improvement of CNC machining of
concave and convex surfaces can include the following:

1. Advanced Cutting Tool Materials: Explore the use of advanced cutting tool materials,
such as ceramics, diamond-coated tools, or hybrid tool materials, to enhance tool life,
reduce tool wear, and improve machining performance for concave and convex surfaces.

2. Adaptive Machining Strategies: Investigate adaptive machining strategies that utilize real-
time data from sensors and monitoring systems to dynamically adjust cutting parameters,
tool paths, and feed rates for optimized machining of concave and convex surfaces.

3. Additive Manufacturing Integration: Explore the integration of additive manufacturing

techniques with CNC machining to enhance the machining process of complex concave
and convex surfaces, allowing for better tool access, reduced machining time, and
improved surface quality.

4. Intelligent Machining Systems: Develop intelligent machining systems that utilize

machine learning algorithms and artificial intelligence to analyze machining data,
optimize cutting parameters, and predict tool acceleration and surface quality for concave
and convex surfaces.

5. Multi-axis Machining Optimization: Investigate the optimization of multi-axis machining

strategies for concave and convex surfaces, considering the dynamic behavior of the
machine tool, tool deflection, and vibration control to improve dimensional accuracy and
surface finish.

6. Green Machining: Focus on environmentally friendly machining techniques, such as

minimum quantity lubrication (MQL) or cryogenic cooling, to reduce machining fluids,
minimize environmental impact, and enhance the sustainability of CNC machining
processes for concave and convex surfaces.

7. Surface Integrity Analysis: Develop comprehensive surface integrity analysis techniques

to evaluate the surface and subsurface properties of concave and convex surfaces,
including residual stresses, microstructure changes, and material properties alterations
induced by machining.

8. Real-time Process Monitoring: Enhance real-time process monitoring capabilities for

CNC machining of concave and convex surfaces by integrating advanced sensors, vision
systems, and data analytics to enable proactive tool condition monitoring, error detection,
and adaptive process control.

9. Virtual Machining and Digital Twins: Utilize virtual machining simulations and digital
twin technologies to optimize the machining process for concave and convex surfaces,
enabling virtual testing and optimization of cutting parameters, tool paths, and machining
strategies before physical machining.

10. Surface Topography Control: Investigate techniques for precise control of surface
topography, such as surface texturing or pattern generation, on concave and convex
41
surfaces using CNC machining. This can include the development of specialized tool
paths, algorithms, or tool geometries to achieve specific surface characteristics.

42
 Chapter 9: Conclusions
During the experiments, the tool acceleration in a ball-end milling process was measured, along
with the cutting parameters and different strategies for tool path selection, using an orthogonal
array:

1. Significance of Step Over: Both the Taguchi analysis and response-surface statistical
analysis indicated that the step over, which refers to the distance between each adjacent
tool path, is the most significant factor affecting tool acceleration in the ball-end-milling
process. This implies that the choice of step over value has a notable impact on the tool
acceleration during the machining process. This means that changing the step over
distance can lead to notable changes in the acceleration experienced by the cutting tool
during the milling process. The step over affects tool acceleration because it determines
the load on the cutting tool. A smaller step over leads to a larger cutting load concentrated
on a smaller area of the tool, resulting in higher acceleration. Conversely, a larger step
over distributes the cutting load over a larger area, reducing the acceleration experienced
by the tool

2. Tool Acceleration for Convex Inclined Surfaces: The results from the confirmation
experiments conducted under optimal conditions revealed that the measured tool
acceleration values for convex inclined surfaces were smaller than the calculated tool
acceleration values. This suggests that the machining process resulted in lower tool
acceleration than initially predicted for convex inclined surfaces. A smaller step over leads
to a higher concentration of cutting forces on a smaller portion of the tool, causing a higher
cutting load per unit area. This increased cutting load results in higher tool acceleration
because the tool needs to withstand the greater forces acting upon it. On the other hand,
when the step over distance is larger, the cutting forces are distributed over a larger area
of the tool. This distribution of forces reduces the cutting load per unit area, thereby
decreasing the acceleration experienced by the tool.

3. Tool Acceleration for Concave Inclined Surfaces: Conversely, for concave inclined
surfaces, the measured tool acceleration values were found to be larger than the calculated
tool acceleration values. This indicates that the actual tool acceleration during the
machining process was higher than the predicted values for concave inclined surfaces.
Additionally, the interaction between the cutting tool and the workpiece during the
machining of concave surfaces can influence the tool acceleration. The curvature of the
surface affects the contact between the tool and the workpiece, potentially leading to
different cutting forces and tool behaviour compared to flat or convex surfaces. These
variations in the cutting forces and contact conditions can result in higher tool acceleration
values than what the calculations predicted.

4. Comparison of Measured and Calculated Values: Despite the differences between the
measured and calculated tool acceleration values, the absolute difference in percentiles
between the two was found to be within a range of 3.57% for both types of inclined
surfaces. This suggests a relatively small discrepancy between the predicted and actual
tool acceleration values. It is important to note that the small discrepancy in percentiles
does not necessarily imply that the predicted values were always lower or higher than the
measured values consistently. The difference could be either positive or negative,
indicating that the predicted values sometimes underestimated and sometimes
overestimated the actual tool acceleration.
43
5. Tool-Acceleration for Convex and Concave Inclined Surfaces: The tool-acceleration
values obtained for machining convex inclined surfaces were smaller compared to those
obtained for machining concave inclined surfaces. This difference can be attributed to the
ease of chip removal in the case of convex surfaces, whereas the cutting tool interacts
with the inner surface and workpiece contacts, resulting in longer cutting edges and higher
tool acceleration. The greater tool acceleration observed in machining concave inclined
surfaces is primarily due to the increased forces exerted on the cutting tool during the
cutting process. These forces are caused by the curvature of the surface, which affects the
contact conditions and cutting dynamics.

6. Tool-Acceleration for Different Tool-Path Styles: The tool-acceleration values were

found to be smaller for contouring tool-path style compared to ramping tool-path style.
This is because the contouring tool-path style involves movements parallel to the axis of
the inclined surface, which helps in effectively removing the chips away from the cutting
zone.

7. Effectiveness of Response Surface Methodology (RSM): The study found that RSM was
effective in identifying and developing significant relationships between cutting
parameters. This indicates that RSM can be a valuable tool for analyzing and optimizing
cutting processes.

8. Correlation Coefficients and Prediction Model: The highest correlation coefficients were
obtained with the tool-acceleration prediction model. This suggests that the prediction
model can be used effectively in related studies for estimating tool acceleration based on
the given cutting parameters.

9. Optimum Combination of Cutting Parameters: The optimum combination of cutting

parameters for response optimization of all surface types was determined to include the
largest cutting velocity, the smallest step over, and the appropriate feed rate. These
parameters were found to result in improved machining performance and quality. when
determining the optimum combination of cutting parameters, it is crucial to consider not
only the cutting velocity, step over, and feed rate but also the selection of the appropriate
tool-path strategy. By combining these factors, machining operations can be optimized to
achieve enhanced performance, improved surface quality, and efficient chip evacuation,
leading to overall better results in terms of productivity and accuracy.

44
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