Optimizing Milling Parameters for Vibration Reduction and Enhanced Performance in Machining Hardened Duplex 2205 Material: Analysis of Vibration, Temperature Profiles, and Power Spectral Density (PSD)

The selection of milling cutter geometry is crucial for achieving successful machining results, particularly when machining hardened materials, where vibration adversely impacts tool life and the spindle of the machine tool. This study aims to enhance milling performance by reducing vibration during operation. The intensity of vibration during the milling process, recording the impact of cutter geometry on vibration magnitude were investigated and highlighting its importance for milling parameters. This approach focused on minimizing vibration to improve performance by selecting inputs based on vibration intensity for optimal results. It is observed that vibration decreases with appropriate cutting conditions. Time-domain analysis of displacement and acceleration revealed that highly positive cutting geometries can lead to unstable behavior and increased vibration magnitudes. Representations of estimate material removal rate (MRR) and cutting forces (Fx, Fy, and Fz), finding a strong correlation between predicted and actual values. Optimization using the Desirability Function Approach was employed to achieve high MRR and low cutting forces. Additionally, the temperature profile, power spectral density (PSD), and Fast Fourier Transform (FFT) of the experimental data were analyzed, confirming the representation's effectiveness in accurately forecasting tool temperatures.