Effect of machining and geometrical parameters on temperature rise during milling of

aluminum (Al)/ silicon carbide (SiC) metal matrix composites

Abstract

High temperature rises at the cutting zone during end milling process was considered to be
detrimental to machining performance characteristics, which results in poor surface finish and
elevated tool wear. This paper deals with measurement of temperature that rises below the
cutting surface during machining of Al/SiC metal matrix composites (MMCs). The machining
conditions of composite materials and geometry of end mill tool is complex, research work
pertain to machinability characteristics are yet to be explored. In this paper, Al356/SiC
composites were fabricated and its machinability characteristics were studied. The input
machining conditions such as spindle speed, feed rate and depth of cut, and different tool
geometries such as helix angle, nose radius and rake angle were varied during machining and
their corresponding output response, temperature rise was observed. Central composite rotatable
response surface methodology experimental design was employed for conducting experiment
with different combination of parameters. The experiments were conducted using vertical
machining centre with high speed steel (HSS) end mill cutter. The temperature rise was measured
using K-type thermocouple fitted at a distance of 2 mm below the cutting surface. A quadratic
empirical model was developed to predict temperature rise in terms of input machining and
geometrical parameters. Analysis of variance (ANOVA) technique was employed to check the
adequacy of the model. The direct and interaction effect of input parameters on temperature rise
were analyzed which helps to determine the significance of each input parameters. Further, D-
optimal design technique was employed to determine the optimal combination of process
parameter for minimum temperature rise.

Keywords: Composites, temperature, response, ANOVA, milling, D-optimal

Chapter I - Introduction

Milling process is primary machining process for producing complicated parts such as
automobile components, gun parts, jewelry, circuit boards and so on. Different types of milling
techniques have been established in industries, end milling is one of the milling processes. End
milling differs from other type of milling process in the way the tooling is used for removing the
materials. It consists of cutting tooth on the sides and end of the shank of the cutter. End mill
tools were employed in applications requiring shape milling, tracer milling, face milling, profile
milling, plunging, etc. Tool geometry and machining conditions plays an important role in
determining the machining performance in end milling operation depending upon the materials.
It becomes critical in the case of machining composite materials. Since the composite materials
is anisotropic in nature, posses non-homogenous structure and high abrasiveness of the
reinforcing materials, becomes difficult to do machining. Proper tool geometry design and
appropriate machining condition need to be adapted for machining composite materials in order
to ensure better surface finish requirements and lessen wear in the cutting tool. In this paper the
effect of machining and geometrical parameters of end milling operations on machining
performance was studied while machining Al/SiC MMCs. The machining characteristic
performance of any metal cutting operation can be directly accessed by surface finish and tool
wear measurement. However online measurement such as vibration picked up at various points
in the machine tools, cutting force during machining and temperature rise at the cutting zone are
also considered for evaluating the machining performance.
Chapter II - Literature review

Temperature at the cutting zone plays an important role in machining process, a high level of
temperature gradients affects the hardness of the work material which results in elevated tool
wear and degrades workpiece surface quality, a medium level of cutting temperature results in
low thermal shock which improves tool life and low level of temperature gradient ensures
surface integrity requirements with low tensile residual stresses. During machining process, the
heat energy is generated at shear plane friction of chip workpiece friction, tool chip interface
friction and tool flank workpiece interface friction [1, 2, 3]. This results in temperature rise in
the chip, tool and workpiece. The main hurdle faced in this study was the measurement of
temperature at the cutting zone. Particularly in milling operation, due to complex nature of the
process measuring cutting temperature is even more difficult. In end milling operations,
Masahiko et al [4], used infrared radiation pyrometer to measure the temperature at the tool chip
interface. Infrared camera can be employed to capture the sequence of temperature generation
during cutting process [5]. Thermocouple method can be directly used to measure temperature in
the cutting zone [6]. Le and Dudzinski [7] employed thermocouple method to measure the
temperature of the machined surface in the subsurface layer. Closer to the vicinity of the tool
chip interface the thermocouple can measure more accurate temperature generated. Thin film
thermocouple embedded in the tool can be used for this purpose [8]. The economic notion of
modifying cutting tool will increase the cost of manufacturing. The temperature gradient in the
cutting zone was obscured due to different chip size, tool chip interface area and complexity in
the tool geometry. The angle between the cutting edges such as helix angle and rake angle
various the cutting forces during machining which result abrupt change in the cutting
temperature. Hence the temperature rise variation depends on the input process parameter such
as machining conditions and geometrical parameters. Interpretation of temperature rise in terms
of machining and geometrical parameters is needed to correlate the machining behavior.

Analyses of temperature rise in the cutting zone addressed by previous researchers are briefed to
understand the importance of this study. Wu and Meyer [9] developed empirical equations to
predict cutting tool temperature in terms of machining parameters such as speed, feed and depth
of cut using response surface method. Yifeng et al [10] proposed an analytical model to predict
cutting temperature based on the moving heat method. The model developed considered the
friction heat energy developed in the shear plane and tool workpiece interface while machining
particle reinforced Al/TiB2 insitu composites. Gosai and Bhavsar [11] developed predictive
model to predict temperature rise in turning operation while machining hardened steel using
central composite design. The input parameters taken into consideration were speed, feed rate
and depth of cut. The changes in geometrical parameters of the cutting tool were not considered
in this investigation. Li et al [12] established an analytical model for heat transfer in face milling
of aluminium alloy based on heat source method. Numerical simulation and experiments using
thermocouple were also conducted to validate the model developed. Pavel et al [13] employed
factorial design to conduct experiment and to develop predictive tool life equation using
temperature measured by thermocouple at the cutting zone. The process parameters considered
were cutting speed, feed rate and depth of cut in face milling operation. Richardson et al [14]
developed an analytical model that predicts the temperature rise in the workpiece during
peripheral milling of aluminium alloys under dry condition. Wu et al [15] proposed an analytical
model through finite element simulation using green function and Osakis theory. The
experiments were conducted in four axis machining centre with double tool end milling cutter
with carbide insert and Inconel718 as workpiece material. The tool temperature was measured
using a single wire thermocouple embedded in the cutting zone. The results obtained with
specific machining parameters conditions were found agreeing with the analytical method.

From the above studies, it is infer that the temperature rise during machining operation at the
cutting zone reduces tool life and poor surface finish. Further, the effects of geometrical
parameters of the cutting tools were not considered. Hence in this study, the empirical
relationship to predict temperature rise in the cutting zone were established in terms of
geometrical parameters such as helix angle, nose radius and rake angle, and machining
conditions such as spindle speed, feed rate and depth of cut. The main objective is to study the
influence of machining conditions and geometrical parameters on temperature rise at the cutting
zone during end milling of Al/SiC MMCs workpiece materials. ½ replicate 6 factors central
composite rotatable response surface design matrix were employed to develop empirical
statistical equations and to determine the optimum levels of process parameters for minimum
temperature rise.
Chapter III – Methodology
3.1 Design of experiments technique

Response surface methodology is a design of experiment techniques based on mathematical and

statistical approach. Earlier application of response surface methodology dates from 1950’s
found in chemical industries, later it extended in various applications and field such as clinical,
biological, social and engineering sciences [16]. This method is employed for determining
empirical equations and analysis of system in which a response measure of performance is
influenced by system process variables. The objective of this method is to optimize the response
performance measure of the system [17]. If all the process parameters were quantitative
variables, then the response ‘y’ is represented as the levels of these parameters as given in the
equation (1)

Response, yj = ψ (x1j, x2j, ……. , x3j) (1)

Where j = 1, 2, ……., N represents the N observation in the factorial experiment, x ij = the level
of the ith factor in the jth observation and ej = residual measures error of the jth observation. The
function ψ is called the response surface. The interpretation of this function gives a detailed
summary of the result of the experiments and also to predict the response for values of the x ij that
were not tested in the experiment. The mathematical form of ψ can be approximated using
polynomial in terms of process variables xij within the experimental region. The advantage of
using polynomial response surface is that they are easy to fit. With a suitable choice of design, a
quadrant surface in 6 variables, which contain 28 coefficients is not formidable a task. But
polynomials are notoriously untrustworthy when extrapolated. A polynomial surface should be
considered as an approximation to ψ within the region.

The general form of a quadratic (second order) polynomial is illustrated by the equation (2)
given below

yu = b0 + + + (2)

The surface contains linear terms in xiu, squared terms in xiu2 and the cross product term xiuxju. b0,
bi, bii and bij are the coefficients of the above equations for constant, linear terms, squared terms
and cross product terms. Central composite designs are response surface design developed
specifically to second order response surface. In order to make curve fitting computation to be
easier, Box and Hunter proposed the criterion of rotatability. The criterion of rotatability is that,
the standard error of the response ‘yu’ at any point on the fitted surface can be computed from the
results of the experiment. Evaluated standard error will be in terms of the coordinate’s x iu of the
point. The standard errors is equal and are at same distance ρ from the center of the region for all
the points. ie.,

x1u2 + x2u2 + ……..+ xku2 = ρ2 = constant (3)

The rotatable design is obtained by conducting experiments at number of points equally spaced
around the circumference of a sphere with center as origin, plus experiments in the replicated
center points. The central composite rotatable design is a 2 k factorial design with added 2K star
points and replicated central points. The star points are considered with one parameter at lower
or higher limits, while the other parameters are set at the middle level. The center points are
replicated to provide degrees of freedom to compute experimental error and to determine the
precision of the responses. The total number of experiment combinations is (2 k factorial points +
2K star points + replicated center points). Rotatable design for any number k of x-variable can be
formed from these three components. The value of β (the distance of centre point to
circumference of spherical space) must be 2k/4 for full replicate and 2(k-1)/4 for ½ replicate.

In this study, helix angle, nose radius and rake angle of cutting tool, and machining conditions
such as spindle speed, feed rate and depth of cut were considered as process parameters (shown
in the table 1), the temperature rise in the cutting zone measured using thermocouple was taken
as response variables. The response temperature rise during milling of Al/SiC MMCs can be
expressed in terms of process parameters such as helix angle (α), nose radius (r), rake angle (γ),
spindle speed (v), feed rate (f) and depth of cut (z) as

Temperature rise, T = ψ (α, r, γ, v, f, z) + eu (4)

With 6 variables and five levels, the selected ½ replicate central composite rotatable design
consist of 53 experiments as shown in the table 2.
 (i) The first 32 combination (1-32) of points given in the table constitute a ½ replicate of 2 6
factorial points comprises of code value of -1 or 1 of each parameter.
(ii) The next 12 combinations (33-44) of points given in the table is called a star points. These
points are extra points incorporated to form a central composite design with β = 2 (6-1)/4 =
2.378.
(iii) The last 9 combinations (45-53) are replicated centre points added to give precision at
the center.

The range of upper limit and lower limit of the each parameters are coded as +2.378 and -2.378
respectively, and for in-between were evaluated from the equation (5) given below [18].

Xi = (5)

Where Xi is the coded values of the process variable X, X is the value of the process variable in-
between the range of Xmin to Xmax, Xmin is the lower limit of the variable and X max is the upper
limit if the variable. The in-between values are coded as -1, 0 and 1.

Table 1. Parameter levels in 6 factor design

Parameter levels
Process parameter Units
-2.378 -1 0 1 2.378
o
Helix angle (α) ( ) degrees 33 40 45 50 57
Nose radius (r) mm 0.1 0.4 0.6 0.8 1.1
o
Rake angle (γ) ( ) degrees 3 6 8 10 13
Cutting speed (v) m/min 32 60 80 100 128
Feed rate (f) mm/rev 0.026 0.04 0.05 0.06 0.074
Depth of cut (z) mm 0.3 1 1.5 2 2.7
Table 2. ½ replicate 6 factor central composite rotatable design matrix

Process parameter Temperature rise (oC)

S.No Observed Predicted
α r γ v f z Error
value value
01 -1 -1 -1 -1 -1 -1 36.2 36.285 -0.235
02 1 -1 -1 -1 -1 1 44.8 44.871 -0.158
03 -1 1 -1 -1 -1 1 24.3 24.233 0.276
04 1 1 -1 -1 -1 -1 35.4 35.399 0.003
05 -1 -1 1 -1 -1 1 36.5 36.557 -0.156
06 1 -1 1 -1 -1 -1 40.4 40.447 -0.116
07 -1 1 1 -1 -1 -1 30.9 30.885 0.049
08 1 1 1 -1 -1 1 39.7 39.723 -0.058
09 -1 -1 -1 1 -1 1 28.5 28.557 -0.200
10 1 -1 -1 1 -1 -1 36.2 36.211 -0.030
11 -1 1 -1 1 -1 -1 26.7 26.649 0.191
12 1 1 -1 1 -1 1 31.8 31.723 0.242
13 -1 -1 1 1 -1 -1 31.6 31.697 -0.307
14 1 -1 1 1 -1 1 44.0 44.047 -0.107
15 -1 1 1 1 -1 1 23.4 23.409 -0.038
16 1 1 1 1 -1 -1 30.8 30.811 -0.036
17 -1 -1 -1 -1 1 1 42.4 42.491 -0.215
18 1 -1 -1 -1 1 -1 41.6 41.681 -0.195
19 -1 1 -1 -1 1 -1 42.3 42.295 0.012
20 1 1 -1 -1 1 1 38.9 38.905 -0.013
21 -1 -1 1 -1 1 -1 47.9 48.019 -0.248
22 1 -1 1 -1 1 1 51.8 51.905 -0.203
23 -1 1 1 -1 1 1 41.4 41.443 -0.104
24 1 1 1 -1 1 -1 40.4 40.381 0.047
25 -1 -1 -1 1 1 -1 45.8 45.831 -0.068
26 1 -1 -1 1 1 1 45.9 45.953 -0.115
27 -1 1 -1 1 1 1 35.5 35.491 0.025
28 1 1 -1 1 1 -1 38.2 38.193 0.018
29 -1 -1 1 1 1 1 48.4 48.491 -0.188
30 1 -1 1 1 1 -1 43.8 43.917 -0.267
31 -1 1 1 1 1 -1 44.5 44.531 -0.070
32 1 1 1 1 1 1 44.9 44.905 -0.011
33 -2.378 0 0 0 0 0 42.7 42.589 0.261
34 2.378 0 0 0 0 0 51.9 51.834 0.127
35 0 -2.378 0 0 0 0 47.3 46.944 0.754
36 0 2.378 0 0 0 0 32.2 32.381 -0.561
37 0 0 -2.378 0 0 0 34.2 34.212 -0.036
38 0 0 2.378 0 0 0 41.3 41.108 0.464
39 0 0 0 -2.378 0 0 27.9 27.766 0.480
40 0 0 0 2.378 0 0 22.6 22.549 0.227
41 0 0 0 0 -2.378 0 34.8 34.795 0.014
42 0 0 0 0 2.378 0 57.7 57.524 0.305
43 0 0 0 0 0 -2.378 34.0 33.908 0.269
44 0 0 0 0 0 2.378 35.4 35.316 0.237
45 0 0 0 0 0 0 35 34.929 0.203
46 0 0 0 0 0 0 34.8 34.929 -0.371
47 0 0 0 0 0 0 34.5 34.929 -1.243
48 0 0 0 0 0 0 35.2 34.929 0.770
49 0 0 0 0 0 0 34.9 34.929 -0.083
50 0 0 0 0 0 0 34.8 34.929 -0.371
51 0 0 0 0 0 0 35.2 34.929 0.770
52 0 0 0 0 0 0 34.7 34.929 -0.660
53 0 0 0 0 0 0 35.2 34.929 0.770

3.2 Experimental arrangement

The workpiece material used for end milling operations is Al356 reinforced with 5% of SiC p
MMCs. The proposed MMCs were fabricated using stir casting method. The commercial
application these materials are found in automobile industries for making brake master cylinder.
The Al356 material was heated and melted in steel crucible at 920 0 C in a steel crucible in
electrical resistance furnace. The molten metal was stirred at a constant speed to from vortex in
the crucible. The preheated SiC particles were added at constant rate in the vortex. The molten
mixed metal is then poured into preheated mold. The produced MMCs were cut into machining
work size of 50mm x 50mm x 50mm using power hacksaw machine. In the prepared workpiece,
a hole of 1 mm was drilled at 4 mm beneath the surface of machining to fit thermocouple to
measure the temperature. K-type thermocouple was used to measure temperature during
machining. The temperature rise was evaluated as the difference between the initial room
temperature and final temperature indicated after machining. HAAS vertical machining center:
model tool room mill machine tool was used conduct the experiment under dry condition. HSS
end mill cutters with different geometries were used to conduct the experiments. The
experimental setup for measuring temperature during end milling operation is shown in the
figure 1. The experiments were conducted as per experimental design matrix in a randomized
manner and the temperature rise for each combination is noted in the table 2.

Figure 1. Temperature measurement during milling operation

3.3 Development of Empirical model

The empirical relationship is the algebraic representation of regression relations between the
response and input process parameters under the investigation. The coefficient value of the
second order quadratic equations was evaluated based on multiple regression method using
statistical software Minitab R16. The estimated regression coefficients and p-values are listed in
the regression table 3.

Table 3. Regression coefficients and p-value

Term Regression Coefficients p-value

Constant 34.929 0
α 1.943 0
r -3.062 0
γ 1.45 0
v -1.097 0
f 4.779 0
 z 0.296 0
α2 2.171 0
r2 0.837 0
γ2 0.483 0
v2 -1.728 0
f2 1.986 0
z2 -0.056 0.03
αr -0.0031 0.926
αγ 0.0031 0.926
αv 0.0031 0.926
αf -2.116 0
αz 1.891 0
rγ -0.0031 0.926
rv -0.0031 0.926
rf 0.428 0
rz -0.878 0
γv -0.009 0.781
γf 0.597 0
γz 0.941 0
vf 1.109 0
vz 0.0031 0.926
fz -0.0031 0.926
S = 0.188357 R2 = 99.97%
R2(pred) = 99.90% R2(adj) = 99.93%

The values of S and R2 depict how well the empirical relation fits the data. S represents the
standard deviation of distance the values of the data lie from the regression line. S value is
calculated as the square root of the mean squared error. The lower the value of S, the prediction
of the developed equation will be better. The calculated value of S is 0.188357, which is lower
that ensures the prediction will be better. The coefficient of determination (R 2) values evaluated,
represent the variation of the process response derived in the equation in terms of the process
input variables. It represents the ratio of sum of squares for regression over the total sum of
squares. R2(adj) and R2(pred) are adjusted values of R2 according to the number of parameters
terms in the model. The greater the value of R 2, the equation derived fits the data. The value of
R2 is 99.7%, which assures the reliability of the model.

The modeling of quadratic response surface equation of temperature rise during milling using
general regression data as shown in the table 3 (full model) is given by

Temperature T = 34.929 + (1.944α) - (3.062r) + (1.45γ) - (1.097v) + (4.779f) + (0.296z) +

(2.172α2) + (0.837r2) + (0.483γ2) - (1.728v2) + (1.986f2) - (0.056z2) – (0.031αr)
 + (0.031αγ) + (0.031αv) - (2.116αf) + (1.891αz) – (0.031rγ) – (0.031rv) +
(0.428rf) - (0.878rz) – (0.009γv) + (0.597γf) + (0.941γz) + (1.109vf) +
(0.031vz) – (0.031fz) (6)
The empirical equation developed can further modified by eliminating the non significant terms
using backward elimination procedure. According to this method, all model terms are given
equal chance of inclusion in the model equation. In this procedure, the p-values computed in the
table 3, can be utilized to determine the statistical significance of each term involved in the
equations. If the p-value computed for a particular term in the equations is smaller than the level
of significance, then the particular term is significant. The value of level of significance
generally used is 0.05 (5%). From the table 3, it was found that the p-value of the terms αr, αγ,
αv, rγ, rv, γv, vz and fz are more than 0.05, such terms are eliminated. Hence the modified final
equation neglecting the non significant terms are given as

Temperature T = 34.929 + (1.944α) - (3.062r) + (1.45γ) - (1.097v) + (4.779f) + (0.296z) +

(2.172α2) + (0.837r2) + (0.483γ2) - (1.728v2) + (1.986f2) - (0.056z2) - (2.116αf) +
(1.891αz) + (0.428rf) - (0.878rz) + (0.597γf) + (0.941γz) + (1.109vf)
(7)

Chapter IV – Conclusion and scope for future work

This chapter, I will give you on Monday after 1.00 pm

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