Industrial Engineering Journal ISSN:2581-4915 1 Optimisation of Machining Parameters On Cutting Force During End Milling Of AISI D2 Tool Steel Using Genetic Algorithm Ravi D Patel 1 , Sanket N Bhavsar 2 1 Research Scholar, Gujarat Technological University, Gujarat, India 2 G. H. Patel College of Engineering, V V Nagar, Gujarat, India Email: raviengineer2007@gmail.com ABSTRACT: In the current scenario, there is a great demand of machining of hard material for today’s dies and moulds manufacturing industries. D grade tool steels are widely used as work material due to its extremely high wear resisting properties as well as high corrosion resisting properties. Nowadays coated tools are widely used for machining of hard materials due to its high wear resistance properties. Cutting force is important factor to reduce tool wear rate during machining of hard material. This research work presents experimental investigation and optimization of machining parameters namely cutting speed, feed, depth of cut and width of cut on cutting force during milling of AISI D2 tool steel using AlCrN coated end mill tool. Design of experiment plan was developed to measure cutting force using response surface methodology (RSM) central composite design method. From experimental analysis, it has been found that cutting speed and width of cut are two dominant cutting parameters that affect the cutting force (Fz). Genetic algorithm was used to optimization of machining parameters to reduce cutting force during end milling. Lowest response reading was measured using GA and also validated it using experimentally. KEYWORDS: AISI D2 Tool Steel, AlCrN coated end mill tool, RSM, ANOVA, GA 1. INTRODUCTION Machining of hard materials is essential task for today’s die manufacturing i ndustries. Selection of machining parameters is very important task for achievable responses [1]. Milling of hardened steel is best alternative to EDM with less production time and higher surface roughness. Cutting force is very crucial output response for machining of hard material with respect to machining cost as well as high product quality [2]. Hard material was machined by cutting tool with high cutting speed resulted in heat generation and higher the temperature attained [3]. Coated tool withstands high impact loading and high temperature with improved wear resistance [4]. Saedon et al [5] analysed experimentally to develop tool life model during micro milling of D2 tool steel and found that cutting speed was main significant parameter for tool life. AISI D2 tool steel was machined and analysed experimental result using ANOVA by Urade et al [6]. Branda et al [7] Presented theoretical and experimental study on heat flow when end milling of hardened steel at high-speed with two types of ball nose end mills. Gaitondea et al [8] investigated on machinability Industrial Engineering Journal Volume 13 Issue 4 * April 2020