Optimizing cutting parameters in inclined end milling for minimum surface residual stress - Taguchi approach

End milling is an important and common machining operation because of its versatility and capability to produce various profiles and curved surfaces. Inclined end milling possesses the capability to translate in all 3 axes but can perform the cutting operation in only 2 of the 3 axes at a time. This research work focuses on investigating the effect of machined surface inclination angle, axial depth of cut, spindle speed and feed rate for better surface integrity in inclined end milling process utilizing titanium coated carbide ball end mill. An optimization method known as Taguchi optimization was used in order to identify the main factors that cause the greatest variation and to determine control parameters in the least variability. Data analysis was conducted using signal-to-noise (S/N) response analysis and analysis of variance (Pareto ANOVA). The optimum condition results obtained through analysis show improvements in residual stress and microhardness in inclined end milling process.