Taguchi based optimization of polyethilene milling parameters based on cutting temperature and surface roughness criteria

Abstract

This paper presents the optimization of face milling parameters for polyethylene (PE) using an end mill on an Emco 55 Mill CNC machine by applying the Taguchi method. The aim was to investigate the influence of machining parameters on cutting temperature, cooling rate, and the surface roughness of the machined surface in both the feed direction and the direction perpendicular to the feed. During the experiment, the machining parameters: spindle speed, feed rate, and depth of cut, were varied at three levels. A thermographic camera was used to measure the characteristic temperatures at a point immediately behind the face milling cutter and after a specified time interval. Based on these measurements, the cooling rate was determined, as it influences the surface roughness of the machined surface. The surface roughness of the polyethylene specimens was evaluated using a surface roughness tester. The measured output geometric parameters included the Arithmetic Mean Roughness (Ra), Root Mean Square Roughness (Rq), Maximum Profile Height (Rz), and Total Profile Height (Rt). In addition, the surface profile geometry, i.e., the roughness profiles, was presented both in the feed direction and perpendicular to it, in accordance with the EN ISO 4287 standard.