Mathematical Modeling of Cutting Force in Milling of Medium Density Fibreboard Using Response Surface Method

Abstract

This paper reports on the development of predicted mathematical model for cutting force (F_c) during side milling of medium density fiberboard (MDF) using uncoated carbide insert. Box-Behnken design (BBD) of experiment, coupled with response surface method (RSM) were employed to establish the cutting force model. Evaluation on the effects and interactions of the machining variables on the cutting force were carried out. The machining variables involved include spindle speed, feed rate, routing width and were denoted by A, B and C respectively. Statistical analysis conducted on the experimental results indicated that the mathematical model for cutting force was adequate within the limits of factors being investigated. After eliminating the insignificant factors or model terms in the reduced model, it was found that factors A, B, C, B² (second order of B), C² (second order of C), were the most significant factors affecting the cutting force. BC (interaction of B and C) and AC (interaction of A and C) are the subsequent significant factors. Three-dimensional plots displaying the interactions between these significant factors were presented. The reduced model was then verified experimentally and statistically using ANOVA. It was evident that Box-Behnken design proved to be an efficient tool in identifying and constructing maps of interactions between the significant factors. Experimental results showed that lower cutting force can be obtained by employing higher cutting speed, low feed rate and lower routing width when side milling MDF using uncoated carbide insert.