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IJMERR 2022 Vol.11(10): 793-800

Numerical and Experimental Analysis of Surface Roughness of AISI D3 Alloy Steel during Pocket Milling Operation

Ilesanmi Daniyan1, Khumbulani Mpofu 1, Adefemi Adeodu2, and Ikenna Damian Uchegbu3
1. Department of Industrial Engineering, Tshwane University of Technology, Pretoria 0001, South Africa
2. Department of Mechanical Engineering, University of South Africa, Florida
3. Department of Mechanical & Mechatronic Engineering, Afe Babalola University, Ado Ekiti, Nigeria

Abstract—Surface roughness is a quality index which partly  determines the ability of a material to meet its service or  functional requirements. In this study, the Response Surface  Methodology (RSM) was used for numerical analysis of the  pocket milling operation of AISI D3 alloy steel and this was  validated via physical experimentations. The physical  experimentations were carried with the aid of a Deckel Maho  DMU80mono BLOCK 5-axis CNC milling machine. The  range of the process parameters selected include; feed rate  between 0.1-0.5 mm/rev, depth of cut between 1- 3 mm and  speed of cut between 150-375 m/min. The RSM generated 20  possible experimental runs while their responses (surface  roughness) were gotten from physical experimentations. The  results of the physical experimentations serve as input into  the numerical analysis carried out using the RSM. This was  used to obtain a predictive model equation for determining  the magnitude of surface roughness as a function of the three  cutting parameters employed (feed rate, depth of cut and  cutting speed). Furthermore, the optimisation of the solutions  obtained generated 10 possible solutions whose desirability  values were equal to 1. The findings of this study may assist  machinist in achieving good surface quality during the  milling operation of AISI D3 alloy steel. 

Index Terms—optimisation, predictive model equation,  process parameters, response surface methodology, surface  roughness 

Cite: Ilesanmi Daniyan, Khumbulani Mpofu, Adefemi Adeodu, and Ikenna Damian Uchegbu, "Numerical and Experimental Analysis of Surface Roughness of AISI D3 Alloy Steel during Pocket Milling Operation," International Journal of Mechanical Engineering and Robotics Research, Vol. 11, No. 10, pp. 793-800, October 2022. DOI: 10.18178/ijmerr.11.10.793-800

Copyright © 2022 by the authors. This is an open access article distributed under the Creative Commons Attribution License (CC BY-NC-ND 4.0), which permits use, distribution and reproduction in any medium, provided that the article is properly cited, the use is non-commercial and no modifications or adaptations are made.