Prediction of tool life in end milling by response surface methodology

This paper presents a study of the development of mathematical models for tool life in end milling steel (190 BHN) using high-speed steel slot drills under dry conditions. The predictive models for tool life have been developed in terms of primary machining variables such as cutting speed, feed and axial depth of cut by response surface methodology. A first-order equation covering a narrow range of the variables and a second-order equation covering a wide range of the variables are presented. Response surface contours were constructed in speed-feed planes and used for determining the optimum cutting conditions for a required tool life. The adequacy of the predictive models was tested by analysis of variance and found to be adequate. (C) 1997 Published by Elsevier Science S.A.