Optimization of face milling process for D3 (Die Steel) by using RSM

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In present study an effort has been made to optimize the CNC milling parameters for D3 material using Response Surface Method (RSM) to maximize material removal rate (MRR) and minimize surface Roughness. As Speed (rpm), Feed (mm/min) and depth of cut (mm) are the main milling parameters to optimize includes operator skill, Tool used, work material, machining conditions, coolant used etc. as noise factors. Therefore considered parameters to optimize in present study are speed, feed and depth of cut. Surface Roughness (Ra) and material removal rate (Ra) are the considered responses. Machining has been done on kitumura 1992 model series CNC vertical milling machine with 4 flute carbide tool on the RSM matrix of input parameters. Further material removal rate (MRR) and surface roughness (Ra) are measured. Then analysis work has been done using regression test. After that we got optimized parameters for CNC milling to get maximum MRR and Minimum Ra. The optimum values of machining parameters - cutting speed, feed and depth of cut were determined as 2210.07 rpm, 850 mm/min and 0.237430 mm respectively.