Effect of Cutting Variables of End Milling Process on Surface Roughness and Machining Vibrations

  • Sachin Ashok Sonawane
  • Akshay P. Pawar
Conference paper


The end milling process is widely used in the manufacturing industries to produce numerous surface features. This research work aims to investigate the influence of spindle speed, feed and depth of cut on surface roughness and machining vibrations while carrying out end milling on AISI D2 die steel using uncoated, and Zirconium Nitride (ZrN) coated ball end mill cutters. Taguchi’s L9 orthogonal matrix is used to conduct the experiments. Analysis of variance (ANOVA) is used to find out significant factors affecting the cutting characteristics. Results of the ANOVA indicate that spindle speed is the most influencing factor concerning the performance outputs. It is observed that ZrN coated ball end mill results in better surface finish and lower machining vibrations.


End milling Surface roughness Machining vibrations Taguchi method ZrN coated ball end mill 


  1. 1.
    Tan G, Zhang Y, Li G, Liu G, Rong Y (2013) Performance of a coated cemented carbide tool in high-speed milling of Ti-6Al-4V alloy. J Adv Manuf Syst 12(2):131–146CrossRefGoogle Scholar
  2. 2.
    Sivasakthivel PS, Sudhakaran R, Rajeswari S (2013) Optimization of machining parameters to minimize vibration amplitude while machining Al 6063 using gray-based Taguchi method. Proc Inst Mech Eng Part B J Eng Manuf 227(12):1788–1799CrossRefGoogle Scholar
  3. 3.
    Kuram E, Ozcelik B (2013) Multi-objective optimization using Taguchi based grey relational analysis for micro-milling of Al 7075 material with ball nose end mill. Measurement 46(6):1849–1864CrossRefGoogle Scholar
  4. 4.
    Kalidass S, Palanisamy P (2014) Experimental investigation on the effect of tool geometry and cutting conditions using tool Wear prediction model for end milling process. J Adv Manuf Syst 13(1):41–54CrossRefGoogle Scholar
  5. 5.
    Sarıkaya M, Yılmaz V, Dilipak H (2016) Modeling and multi-response optimization of milling characteristics based on Taguchi and gray relational analysis. Proc Inst Mech Eng Part B J Eng Manuf 230(49):1049–1065CrossRefGoogle Scholar
  6. 6.
    Bhopale NN, Pawade RS, Joshi SS (2017) Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology. Proc Inst Mech Eng Part B J Eng Manuf 231(4):628–640CrossRefGoogle Scholar
  7. 7.
    Costa DMD, Belinato G, Brito TG, Paiva AP, Ferreira JR, Balestrassi PP (2016) Weighted principal component analysis combined with Taguchi’s signal-to-noise ratio to the multiobjective optimization of dry end milling process: a comparative study. J Braz Soc Mech Sci Eng 39(5):1663–1681CrossRefGoogle Scholar
  8. 8.
    Celik YH, Karabiyik A (2016) Effect of cutting parameters on machining surface and cutting tool in milling machine of Ti-6Al-4V alloy. Indian J Eng Mater Sci 23(5):349–356Google Scholar
  9. 9.
    Tamiloli N, Venkatesan J (2016) Investigation on effect of machining parameters of end milling on surface finish and temperature using Taguchi technique. J Manuf Sci Prod 16(4):255–261Google Scholar
  10. 10.
    Babu PGHV, Murthy BSN, Venkatarao K, Ratnam C (2017) Multi-response optimization in orthogonal turn milling by analyzing tool vibration and surface roughness using response surface methodology. Proc Inst Mech Eng Part B J Eng Manuf 231(12):2084–2093CrossRefGoogle Scholar
  11. 11.
    Razak NH, Rahman MM, Kadirgama K (2017) Cutting force and chip formation in end milling operation when machining nickel-based superalloy, Hastelloy C-2000. J Mech Eng Sci 11(1):2539–2551CrossRefGoogle Scholar
  12. 12.
    Rajeswari B, Amirthagadeswaran KS (2017) Experimental investigation of machinability characteristics and multiresponse optimization of end milling in aluminium composites using RSM based grey relational analysis. Measurement 105:78–86CrossRefGoogle Scholar
  13. 13.
    Tomadi SH, Ghanib JA, Che Haronb CH, Mas Ayua H, Dauda R (2017) Effect of cutting parameters on surface roughness in end milling of AlSi/AlN metal matrix composite. Procedia Eng 184:58–69CrossRefGoogle Scholar

Copyright information

© Springer Nature Switzerland AG 2020

Authors and Affiliations

  • Sachin Ashok Sonawane
    • 1
  • Akshay P. Pawar
    • 1
  1. 1.SVERI’s College of EngineeringPandharpurIndia

Personalised recommendations