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Procedia Materials Science 6 (2014) 612 622

3rd International Conference on Materials Processing and Characterization (ICMPC 2014)

Experimental Study of Cutting Forces in Ball End Milling of

Al2014-T6 Using Response Surface Methodology
Mithilesh Kumar Dikshita*, Asit Baran Puria, Atanu Maityb
a
Department of Mechanical Engineering
National Institute of Technology Durgapur
Durgapur, India
b
Advance design & Optimization
CSIR-Central Mechanical Research Institute
Durgapur, India

Abstract
In the present research, the influence of cutting parameters (cutting speed, feed per tooth, axial depth of cut and radial depth of
cut) during ball-end milling of Al2014-T6 under dry condition has been studied. The experimental plan was based on face
centred, rotary central composite design (RCCD). Three cutting force components i.e. tangential, radial and axial forces were
measured and then analysis of variance (ANOVA) is performed. It has been found that the quadratic model is best fitted for
prediction of the force components. The analysis of result shows that the cutting forces increases as increase in feed per tooth and
axial depth of cut but decreases with increase in cutting speed. Radial depth of cut has significant effect on the cutting force
components.

2014Elsevier
The Authors.
Published
byaccess
Elsevier
Ltd.
2014
Ltd. This
is an open
article
under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection
and peer-review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET).
Selection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)
Keywords: ANOVA; Cutting forces; Milling; RSM

1. Introduction
Ball-end milling is a versatile milling process in generating complex shapes of high quality at high productivity,
Arshad A. Sonwane et al.(2010). It is widely used in the automobile, aerospace, die/mold industries, machining of
propellers and turbine blades. In machining process, errors may occur due to the problems in machine tool,
machining methods and machining process itself.
* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 .

E-mail address: dixit.mithilesh@gmail.com

2211-8128 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)
doi:10.1016/j.mspro.2014.07.076

Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

The major problems for the machining processes are the errors that arises due to high cutting forces. Thus, to ensure
the stability of machining system and optimization of process parameters, cutting force model has become an
essential step to understand the behavior of cutting processes as reported by Yuwen Sun et al.(2009). Tsan R. Line
(2002) studied the experimental design and performance analysis of TiN coated carbide tool in face milling of
stainless steel using Taguchi method using three levels of cutting parameters viz. cutting speed, feed rate and depth
of cut. Bouzakis, K. D., et al. (2009) have reported that the cutting forces increased with increase in fee and
increased in depth of depth of cut considering input parameters like cutting speed, feed and depth of cut. Tangchao et
al. (2010) studied empirical models and optimal cutting parameters for cutting forces and surface roughness in hard
milling of AISI H13 steel based on Taguchis method with four factors, cutting speed, feed, radial depth of cut and
axial depth of cut and four-level orthogonal experiment was employed. They have reported that axial depth of cut
and feed are the two dominant factors affecting the cutting forces. Turned L. Ginta (2009) employed central
composite design to study the surface roughness models in end milling of Titanium alloy in terms of three factor,
cutting speed, axial depth of cut and feed. J. Vivancos et al. (2004) applied factorial design of experiment with
technique of regression to study the machining parameter selection in high speed milling of hardened steel for
injection molds considering axial depth of cut, radial depth of cut, feed per tooth and cutting speed as input
parameters. Kuang-Hua Fuh et al. (1997) considered spindle rotation, feed per tooth, axial depth of cut, and radial
depth of cut as input parameters for orthogonal rotatable central composite design for predicting milling force model
for high speed end milling operation with flat end cutter. Most of the experimental investigations have been
conducted using two-level and three level factorial design and Taguchi design method to study the influence of
cutting parameters on cutting forces. In two-level factorial design, only linear relationships of model can be
identified. For the study of nonlinearity present in the output characteristics three and four-levels of each factor are
required. The number of experimental trial are very large in factorial and Taguchi method as the number of factors
increases. A central composite design is usually better which requires fewer experiments.
In the present study, rotary central composite (RCCD) was considered. The slot milling experiments were
conducted on Al2014-T6 using TiAlN coated solid carbide ball-end milling cutter under dry condition to analyze
and compare the measured cutting forces in tangential, radial and axial direction. The influence of axial depth of cut
(AP), radial depth of cut (Ae), feed per tooth (fZ), and cutting speed (VC) as input parameters were studied and
regression equations correlating with output ware established based on experimental data. The analysis were
performed in MINITAB 16 software.
Nomenclature
dof
degree of freedom
FX
tangential cutting force (N)
FY
radial cutting force (N)
FZ
axial cutting force (N)
RCCD rotary central composite design
RSM
response surface methodology
SS
sum of square
Adj SM adjusted square mean
fz
feed per tooth (mm/tooth)
AP
axial depth of cut (mm)
Ae
radial depth of cut (mm)
VC
cutting speed (m/min)
2. Response surface methodology
RSM is a collection of mathematical and statistical techniques that are useful for the modelling and analysis of
problems in which a response of interest is influence by several variables and objective is to optimize this response.

613

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Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

RSM design also help in quantifying the relationships between two or more measured responses and the input
factors. Regression analysis should be performed to determine an existing relationship between the input factors and
response variables statically. A response variable Y is postulated to be a random variable and k input variables x 1,
x2, x3xk are presumed to be continuous. On performing the regression the functional relationship between input
factor and response variables, it is possible to represent the independent input factors (x 1, x2, x3xk) in quantitative
form which have a functional relationship with response Y,D. C Montgomery(1997). This may be written as:

Y = f x1 , x2 , x3 , ..., xk

(1)

Where measures the experimental error.

The second order polynomial in independent variable is given by:
k
k
k k
Y = 0 + i xi + ii xi2+ ij xi x j (2)
i=1
i=1
i=1 j=1
The least square technique is being used to fit a model equation containing the regressions or input factors by
minimizing the residual error by measuring sum of square deviations between the actual and estimated response
model. This involves the regression coefficients of the model variables including the intercepts or constant terms.
The calculated model equations need to be tested for statistical significance. The statistical significance can be
performed through following steps.
1. Test of significance of the regression model.
2.
Test of significance on the individual model coefficients.
3. Test of lack of fit.
The detailed procedure of statistical significance test can be found in the book by D. C Montgomery (1997).
3. Experimental details
Milling is an intermittent multi-point cutting operation, in which each tooth is in contact with the workpiece for
fraction of a spindle period. Tooth contact time varies as a function of width of cut, spindle speed and number of
flutes. Unlike turning where chip thickness is constant, milling tool follows a trochoidal path due to the
simultaneous feed and rotation motion leading to a variable chip thickness over a revolution of the cutting tool. As
shown in the Fig. 2, variation of chip thickness result in the periodical change in the cutting forces acting on the tool
tooth along with the entry and exit of the cutting edge.

Fig. 1. Experimental setup

Fig. 2. Average cutting force

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Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

3.1. Workpiece Material

The slot milling performance tests were performed on aluminum alloy, Al2014-T6 which covers a wide variety of
applications such as automotive and aerospace industries. The dimension of workpiece 160mm100mm100mm
was used in this study.
Table 1. Experimental parameters and their levels
No.

Factors

unit

Coded level
-2

-1

Feed (X1)

mm/tooth

0.02

0.07

0.12

0.17

0.22

Axial depth of
cut (X2)

mm

0.2

0.6

1.4

1.8

Radial depth of
cut (X3)

mm

0.1

0.3

0.5

0.7

0.9

Cutting speed
(X4)

m/min

75

100

125

150

175

Responses (N)
Fy

Fz

-22.01
-37.13
-57.96
-84.17
-57.08
-95.12
-110.22
-157.89
-19.03
-26.98
-54.21
-68.07
-39.91
-66.12
-89.96
-126.95
-38.32
-94.04
-24.16
-124.02
-15.01
-109.81
-90.06
-59.13
-76.07
-75.02
-75.02
-76.04
-75.03
-76.06
-76.98

45.12
78.16
80.91
124.02
78.23
117.18
114.08
161.83
46.32
55.98
80.81
98.03
66.32
88.45
101.78
126.21
62.05
129.76
49.85
132.35
52.01
119.91
103.98
78.91
98.04
98.91
97.02
98.06
100.13
102.31
100.08

Run
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

X1

Table 2. Design layout and experimental results for cutting force components.
Coded levels
Actual values
X2
X3
X4
fz
Ap
Ae
Vc
Fx

-1
1
-1
1
-1
1
-1
1
-1
1
-1
1
-1
1
-1
1
-2
2
0
0
0
0
0
0
0
0
0
0
0
0
0

-1
-1
1
1
-1
-1
1
1
-1
-1
1
1
-1
-1
1
1
0
0
-2
2
0
0
0
0
0
0
0
0
0
0
0

-1
-1
-1
-1
1
1
1
1
-1
-1
-1
-1
1
1
1
1
0
0
0
0
-2
2
0
0
0
0
0
0
0
0
0

-1
-1
-1
-1
-1
-1
-1
-1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
-2
2
0
0
0
0
0
0
0

0.07
0.17
0.07
0.17
0.07
0.17
0.07
0.17
0.07
0.17
0.07
0.17
0.07
0.17
0.07
0.17
0.02
0.22
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12
0.12

0.6
0.6
1.4
1.4
0.6
0.6
1.4
1.4
0.6
0.6
1.4
1.4
0.6
0.6
1.4
1.4
1
1
0.2
1.8
1
1
1
1
1
1
1
1
1
1
1

0.3
0.3
0.3
0.3
0.7
0.7
0.7
0.7
0.3
0.3
0.3
0.3
0.7
0.7
0.7
0.7
0.5
0.5
0.5
0.5
0.1
0.9
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

100
100
100
100
100
100
100
100
150
150
150
150
150
150
150
150
125
125
125
125
125
125
75
175
125
125
125
125
125
125
125

60.18
96.13
110.08
160.12
85.23
132.93
134.86
210.23
56.47
78.13
94.33
141.92
58.96
99.01
112.05
160.80
56.24
151.98
55.98
176.92
67.87
121.06
144.14
95.14
104.30
105.30
108.16
105.91
110.15
106.93
104.22

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3.2. Cutting conditions and experimental plan

In the present study, a set of slot milling experiments were performed on Mikron-VCP710 vertical three axis CNC
milling machine. The cutting tool used was TiAlN coated (monolayer) 2 flute solid carbide ball-end milling cutter of
diameter 10 mm (Sandivk coromant CoroMill Plura, R216.42-10030-Al10G 1620), helix angle 300 and rake angle
40. Dry machining was employed as dry machining has been considered as the machining of the future due to
environmental safety, P. S. Sreejith et al.(2000). In this study the influence of machining parameters on the cutting
forces, four parameters, feed per tooth (fz), axial depth of cut (Ap), radial depth of cut (Ae) and cutting speed (Vc) are
considered. These parameters affect the cutting forces, they have been chosen as the independent input variables.
The coded values of the parameters are shown in the Table 1.A standard RSM design called rotary central composite
design (RCCD) was used to study the slot milling process whereby the factorial portion is full factorial with full
replication of the factors at all levels. The model consist of 16 cube points, 7 central points and 8 axial points. The
value of was 2. The response variables studied are tangential (F X), radial (FY), axial (FZ). As shown in the Table 2,
the experimental design matrix consists of 31 runs and response variables are F X, FY, and FZ. The cutting forces
were measured using Kistler three component dynamometer of type 9257B connected with multichannel amplifier
of type 5011B and a data acquisition system. The arrangement of the experiment is shown in the Fig. 1.
3.3. Experimental setting
The axis of the dynamometer was aligned with the axis of the machining table of the vertical CNC milling centre
before conducting the experiments. Firstly the I-shaped workpiece top surface was machined with the flat end
milling cutter having 8 inserts. To sure the flatness of the newly machined surface, it was measured with noncontacting laser probe. The difference in the flatness was 0.002 micrometre. The set of 31 experiments were
performed in two steps on the I-shaped Al2014-T6 workpiece of length 160 mm and width 100 mm. In the first step
the whole length of the workpiece was divided into 16 grids evenly. After collecting the desired data the workpiece
was again prepared with the similar way stated above. In the second step 15 experiments were performed. The width
of cut in each set of experiment was 10 mm. the experiment was performed in standard order as shown in the Table
2.
3.4.Cutting force data processing
For each experiment, three sets of cutting force components data were measured in tangential (Fx), radial (Fy),
axial (Fz) directions respectively. After recording the forces, average values of forces were analyzed between 0 and
(half rotation of the cutting tool) over all width of the cut and considering maximum cutting force in half rotation.
Since the data were too much the average force was taken on five samples of stable cutting between 0 and as
shown in the Fig. 2.
4.Results and discussion
The experimental results are shown in the Table 2 along with experimental design matrix. These results were input
into the MINITAB 16 software for further analysis following the steps in section 2. On analyzing the response
surface design, the examination of the Fit summary output shows that the quadratic model is statistically significant
for FX, FY, and FZ as shown in the Table 3 and hence it will be used for further analysis.In the present study, the
desired level of confidence was considered to be 95%. The F-value for the lack of fit of developed model should not
exceed the standard tabulated F-value then the relationship may be considered to be adequate. At 95% confidence
limit, the standard tabulated F-value is 4.06. The calculated F-value at 95% confidence limit of lack of fit of the

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Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

model developed is 3.57, 2.31 and 2.80 for FX,FY, and FZ respectively as shown in the Table 3. Thus the model is
adequate. The p-value of lack of fit for FX,FY, and FZ is 0.066, 0.159 and 0.110 respectively which are greater than
0.05, thus the lack of fit is insignificant. The estimated regression coefficient of FX,FY, and FZ are shown in Table 5.
The p-value of the terms X12, X2X3, and X2X4forFX is greater than 0.05. Thus, these terms are insignificant.
Similarly, the terms X22, and X42 for FY, and X12, X2X3,and X2X4forFZ are insignificant. The insignificant terms are
reduced by backward elimination process one by one. The resulting ANOVA table of FX,FY, and FZ for the reduced
model is shown in the Table 4. Table 4 indicates that the reduced model is still adequate. The reduced estimated
regression coefficient of FX,FY, and FZ,after backward elimination process are shown in the Table 6.
Table 3. Analysis of variance for cutting force components FX, FY, andFZ.
Cutting force components

F-value

p-value

R2

R2(adj.)

(Lack of Fit)
Tangential force (FX)

3.57

0.066

99.55%

99.15%

Radial force (FY)

2.31

0.159

99.95%

99.91%

Axial force (FZ)

2.80

0.110

99.56%

99.17%

Table 4. Analysis of variance for cutting force components FX, FY, and FZ. (Reduced model backward elimination)
Cutting force components

F-value

p-value

R2

R2(adj.)

(Lack of Fit)
Tangential force (FX)

3.25

0.080

99.55%

98.20%

Radial force (FY)

2.71

0.115

99.94%

99.90%

Axial force (FZ)

2.84

0.104

99.44%

99.12%

Table 5. Estimated regression coefficient for FX, FY, and FZ.

Term

Fx (N) Fy (N)Fz (N)

Coefficients

p-value

Coefficients

p-value

Coefficients

p-value

Constant

106.42

0.000

-75.74

0.000

99.22

0.000

X1

23.27

0.000

-13.47

0.000

15.48

0.000

X2

29.13

0.000

-24.40

0.000

19.87

0.000

X3

12.62

0.000

-23.47

0.000

15.85

0.000

X4

-11.92

0.000

8.00

0.000

-7.74

0.000

X12

-0.029

0.965*

2.35

0.000

-0.76

0.131*

X2

3.056

0.000

0.37

0.065*

-1.97

0.001

X32

-2.44

0.002

3.29

0.000

-3.25

0.000

X42

3.85

0.000

0.24

0.207*

-1.88

0.001

X1X2

4.77

0.000

-2.33

0.000

1.79

0.013

X1X3

3.53

0.001

-5.36

0.000

1.88

0.010

X1X4

-3.18

0.002

2.62

0.000

-5.58

0.000

X2X3

1.64

0.078*

-4.22

0.000

-0.27

0.671*

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Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

X2X4

-1.51

0.101*

0.73

0.010

-0.77

0.247*

X3X4

-4.79

0.000

4.02

0.000

-2.59

0.001

* Insignificant

Table. 6. Estimated regression coefficient for FX, FY, and FZ. (Reduced model, backward elimination)
Term

FX FY FZ
Coefficients

p-value

Constant

106.39

0.000

X1

23.27

X2

Coefficients

p-value

Coefficientsp-value

-75.16

0.000

98.43

0.000

0.000

-13.47

0.000

15.48

0.000

29.13

0.000

-24.40

0.000

19.87

0.000

X3

12.62

0.000

-23.47

0.000

15.85

0.000

X4

-11.92

0.000

8.00

0.000

-7.74

0.000

X12

2.29

0.000

X22

3.05

0.000

-1.88

0.001

X32

-2.43

0.001

3.23

0.000

-3.17

0.000

X42

3.85

0.000

-1.80

0.002

X1X2

4.77

0.000

-2.33

0.000

1.79

0.014

X1X3

3.53

0.001

-5.36

0.000

1.88

0.010

X1X4

-3.18

0.002

2.62

0.000

-5.58

0.000

X2X3

1.64

0.069

-4.22

0.000

X2X4

-1.51

0.091

0.73

0.015

X3X4

-4.79

0.000

4.02

0.000

-2.59

0.001

R2 is a measure of the amount of reduction in the variability of response obtained by using the regressor variables in
the model. A large value of R2does not necessarily imply that the regression model is good. Adding a variable to the
model will always increase in R2. Because R2 always increase as terms are added to the model, adjusted R2 (R2 Adj)
is preferred. It often decreases if unnecessary terms are added,D. C Montgomery(1997).In the present study the R2
(Adj) value is high and close to unity, which is desirable. When R2 (Adj) approaches unity the response model fits
the actual data better. The R2 (Adj) is close to unity for the reduced model FX, FY, and FZ as shown in the Table 4.
The value of R2 (Adj) of reduced model for FX = 0.9820 indicates that the 98.20% of the total variability is
explained by the model after considering the significant terms. When the difference between R 2 and R2 (Adj) is
large, there will be good chance that insignificant terms have been included in the model. As indicated in the Table
4, for tangential cutting force the difference of R2 and R2 (Adj) is reasonably very low equal to 0.0135. Similarly for
FY, 99.90% of total variability is explained by the model and 99.12% of total variability is explained by the model
for FZ as shown in the Table 4. The normal probability plot of the residuals for the cutting force components are
shown in the Fig. 3-5. From the figures revel that the residual fall on a straight line which indicate that the errors are
normally distributed.

619

99

99

95

95

90

90

80

80

Normal % probability

Normal % Probability

Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

70
60
50
40
30
20

70
60
50
40
30
20

10

10

-8

-6

-4

-2

0
Residual

-2

-1

Residual

Fig. 3 Normal plot of residuals for FX data

Fig. 4 Normal plot of residuals for FY data

99

95

Normal % probability

90
80
70
60
50
40
30
20
10
5

-5.0

-2.5

0.0

2.5

5.0

Residual

Fig. 5. Normal plot of residuals for FZ data

The surface plot for the cutting force components are shown in the Fig. 6. Cutting forces have curvilinear profile in
accordance to the quadratic model fitted. From the figures, it can be seen that the surface curvature of tangential and
axial cutting forces follow the same trend. Tangential and axial cutting forces decrease with increase in cutting
speed and increases with increase in feed per tooth and axial depth of cut. Cutting metals at high cutting speeds
result in highly localized temperature, stresses and strain rates resulting in a decrease in chip thickness,N. A.
Abukhshim et al.(2006). Highly localized temperature leads to thermal softening of the workpiece material and
decrease in chip thickness and allowing greater deformation results corresponding decrease in cutting force. As the
feed per tooth increases, more material will available at the cutting edge and increase in chip thickness which results
in the increase in cutting forces. Due to the complex geometry of the ball part of the ball-end milling cutter, increase
in depth of cut increases the axial engagement of the cutting edge with the workpiece material results the increase in
chip thickness which leads to the increase in cutting forces. Axial depth of cut and feed per tooth contribute 47.49 %
and 30.30 % respectively in tangential cutting force (FX). For axial cutting force (FZ) the contribution of depth of cut
is39.52 %, feed per tooth is 24.01 % and radial depth of cut is 25.16 %. Radial cutting force (F Y) is influenced
greatly by axial depth of cut (40.76 %), radial depth of cut (37.69 %) and feed per tooth (12.43 %). Axial depth of
cut is the dominant cutting parameter among the all four parameters that affects the three cutting force components.
From the result it is found that the radial cutting force is significantly affected by the radial depth of cut. The
regression equations for the cutting force components after removing the significant terms in coded level are as
follow:

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Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

F = 106.39 + 23.27X + 29.13X + 12.62X -11.92X + 3.05X 2

1
2
3
4
2
X
2
2

- 2.43X3 + 3.85X 4 + 4.77X1X 2 + 3.53X1X3 - 3.18X1X 4 - 4.79X3X 4

75.16 + 13.47X + 24.40X + 23.47X - 8X - 2.296X 2 - 3.23X 2 + 2.33X X

1
2
3
4
1
3
1 2
F
=
Y
+5.36X
X
2.62X
X
+
4.22X
X
0.73X
X
4.02X
X

1 3
1 4
2 3
2 4
3 4

2
2
FZ = 98.43 + 15.48X1 + 19.87X 2 + 15.85X3 - 7.74X 4 -1.88X 2 - 3.17X3

2
+ 1.80X 4 + 1.79X1X 2 + 1.88X1X3 - 5.58X1X 4 - 2.59X3X 4

(3)

Mithilesh Kumar Dikshit et al. / Procedia Materials Science 6 (2014) 612 622

Figure. 6. Surface plot for three different force components: Tangential force (A and B), radial force (C and D), axial force (E and F).

5. Conclusion
The following conclusion are drawn for an experimental investigation of the effect of cutting speed, feed per tooth,
axial depth of cut and radial depth of cut on the cutting force components:
x

Rotary central composite design has proved to be successful technique to predict the cutting force
component in balled end milling.

Axial depth of cut is a dominant parameters that affect the tangential, axial and radial cutting forces.

Radial depth of cut has more influence on axial and radial cutting forces as compared to feed per tooth.

Quadratic model is fitted for all the three cutting force components and provide accurately predicted
values of cutting force components close to the experimental value.

Acknowledgements
The authors acknowledge the support given by the vertical milling center at CSIR-CMERI, Durgapur India and
specially to Mr. S. Y Pujar for his collaboration in conducting experiments.
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