TOME VI (year 2008), FASCICULE 3, (ISSN 1584 – 2673) 171 RESPONSE SURFACE METHODOLOGI CAL APPROACH FOR THE PREDI CTI ON OF TANGENTI AL CUTTI NG FORCES I N END MI LLI NG OF STAI NLESS STEEL 1,2. Anayet U. PATWARI, 2. A.K.M. Nurul AMIN, 3. Waleed F. FARIS 1. Department of Mechanical & Chemical Engineering, IUT, Dhaka 2. Department of Manufacturing and Materials Engineering 3. Department of Mechanical Engineering, Faculty of Engineering, International Islamic University Malaysia, Kuala Lumpur, MALAYSIA A b stra c t: The present paper discusses a response surface methodological approach for the prediction of tangential cutting force produced in end-milling operation of Stainless steel (SS304). It is difficult to predict accurately the cutting forces encountered in end milling operations due to large number of independent variables involved. In this work, an approach was undertaken to develop mathematical model based on RSM design for predicting the average tangential cutting force in end milling of SS304 in terms of cutting parameters cutting speed, feed rate, and axial depth of cut. All the individual cutting parameters affect on cutting force as well as their interaction are also investigated in this study. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. This paper presents an approach to predict cutting force model in end milling of stainless steel using coated TiN insert under dry conditions and full immersion cutting. Ke ywo rd s: Cutting Forces, RSM, coated TiN, model 1. INTRO DUC TIO N Details of the metal cutting forces are required not only for the design of machine tools and cutting tools, but also for the determination of the cutting conditions for the various machining operations, especially for the programming on the CNC machining. It is necessary to select appropriate cutting conditions but avoid conditions that lead to excessive cutter deflection and cutter breakage, which are becoming increasingly important in finish machining. The traditional mechanistic approach is often used in predicting the cutting forces, where the cutting coefficients are identified through empirical curve fit to measured average milling forces. Peripheral milling is a widely used metal removal process in automobile, aerospace, textile machinery and other manufacturing industries for the roughing and finish cutting of profiled components, such as aircraft structural parts, dies and molds. The contour accuracy of the milled profiles is influenced by a number of factors including tool deflection, work-piece deflection, machine tool geometric errors, thermal effect, tool wear, etc. Among these factors, tool deflection caused by the cutting forces is the most dominant factor [1–3]. So a proper model of cutting forces provides a basis for surface accuracy prediction and improvement [4–6]. Presently developed cutting force models generally resort to the integrations of local cutting forces along the cutting flutes over cutter rotational cycles by numerical calculation [7], convolution analysis [8] and analytical formulation [9]. These models are obtained on condition of steady state cutting, in which the