Effect of Milling Parameters on Frictions when Milling Hastelloy C-22HS: A FEM and Statistical Method

This study was developed the Finite Element Model (FEM) and Response Surface Method (RSM) to investigate the effect of milling parameters on frictions when milling Hastelloy C-22HS. This study gain better understanding of the friction distribution in metal cutting process. The RSM was used to minimize the number of simulation. The contour plot from RSM shows the relationship between input variables including the cutting speed, feed rate and axial depth and responses including the friction coefficient, friction angle, friction stress and friction force. Feed rate, axial depth and cutting speed play major role to generate high friction coefficient, friction angle, friction stress and friction force. When all the variables at highest value the friction stress become larger, on the other hand reduce the feed rate and increase other variable, it cause high friction coefficient, angle and force. The combination of numerical analysis and statistical method are very useful to analysis the distribution of friction in milling. It is suitable to use middle value of cutting speed, feed rate and axial depth when milling same type of materials.

Key words: Finite element analysis, response surface method, milling, friction,
Hastelloy C-22HS

M.M.Noor