Metal Removal Technology: Processes and Methods of Milling

This research delves into the innovative and cost-effective option of metal removal technology through milling. It explores different processes and methods of milling for precision features and surface refinement. The study includes experimentation with suitable time schedules and workpiece materials. The article also discusses the types of milling machines and cutting tools used for metal removal. Subject: Metal Removal Technology, Course Code: N/A, Course Name: N/A, College/University: N/A

Running head: METAL REMOVAL TECHNOLOGY
Metal Removal Technology
Name of the student:
Name of the university:
Author Note

1METAL REMOVAL TECHNOLOGY
Executive summary
The process of metal removal is an innovative economic option regarding primary manufacturing.
Despite the costs of tooling and least setup the huge machining times are requires as it is cost
effective for high amounts. Due to high tolerances and outcomes of the surfaces, as offered by
machining it is used to add and refine precision features for present part. In this research different
processes of metal removal through milling are discussed. Apart from this different process of
milling methods are analyzed. These results are done through processes of experimentation with
suitable time schedule that are analyze on the study.

2METAL REMOVAL TECHNOLOGY
Table of Contents
1. Introduction:......................................................................................................................................4
2. The motivation behind the research:..................................................................................................5
3. Conducting of literature review:........................................................................................................6
3.1. The process of milling:...............................................................................................................6
3.2. Basic of milling machines:.........................................................................................................7
3.3. Reducing milling trips and time with milling cutting edges:.....................................................8
3.4. Advanced milling with developed cutting edges and structure:.................................................8
3.5. Types of Milling Machines.........................................................................................................8
3.6. Problem statement:...................................................................................................................10
3.7. Milling operations:....................................................................................................................10
3.8. Taping operations:....................................................................................................................12
3.9. Manual vertical milling machine:.............................................................................................13
3.10. Tooling in milling:..................................................................................................................14
3.11. Meeting strict regulations and promoting environmental stewardships:................................16
3.12. Reducing overall selenium to various low single-digit ppb levels with one step process:.....17
3.13. Material processing:................................................................................................................18
4. Methods of milling for the research:...............................................................................................21
5. Experimentation:..............................................................................................................................22
5.1. Work piece materials used:.......................................................................................................23

3METAL REMOVAL TECHNOLOGY
5.2. Design of experiment (DOE):...................................................................................................24
5.3. Equipment used:.......................................................................................................................24
5.4. Data analysis:............................................................................................................................24
6. The current progresses:....................................................................................................................25
7. Timeline of the current project:.......................................................................................................27
8. Conclusion:......................................................................................................................................29
9. References:......................................................................................................................................31

4METAL REMOVAL TECHNOLOGY
1. Introduction:
The metal removal process or machining is the most financial option as far as primary
manufacturing is concerned. This has been paid for and cutting away and discarding the achievement
of ultimate part. Moreover, despite the tooling costs and least setup, the long machining times has
been needed and thus it is cost prohibitive for huge quantities. Thus metal removal is used for
restricted amount as in fabrication of various prototypes and custom tools. This is for manufacturing
procedures. It is also used commonly as a secondary methods. Here minimal material is eradicated
and overall cycle time is short (Zaretalab et al. 2018). Moreover, because of huge tolerances and
surfaces outcomes, offered by machining, it is utilized for adding and refining various precision
features for current part and smoothing a surface for efficient finish.
Metal removal also involves various procedures, where every elements are removed from the
part or work-piece. Most common metal removal processes are denoted as the traditional machining.
These have been mechanically cutting smaller chips of metals through sharp tools. Besides, non-
traditional machining procedures are used as thermal or chemical means to remove materials. The
traditional processes are placed into three type of categories. This is abrasive machining, multi-point
cutting and single point cutting (Li et al. 2015). Besides, under a given process of various activities
that are done. This has been using particular cutting motions and tools. This machining part has been
needing various operations done with proper planning sequence for developing intended elements.
Milling is the metal removal method through using rotary cutters for removing materials
from work-pieces. This is done through advancing the cutter to work-piece at specific directions.
This is held at a specific angle that is relative to the axis of their tool. In this research various metal
removal processes through milling are demonstrated. Further, various processes of milling methods

5METAL REMOVAL TECHNOLOGY
are analyzed. Further, the results are analyzed and processes of experimentation with proper time
schedule is discussed.
2. The motivation behind the research:
The study aims to review printed materials. This is helpful to gain knowledge and understand
primary milling procedures and theories. Besides, this is useful to become aware of latest
technologies and functions and features of machine centers. This primary vertical know mill
machine is examined, parameters of successful metal removal are recognized. Here applying the
technology to milling is explained. Various machine center functions and features are also
highlighted. Besides different cutting tools, work-changing and work-holding devices are been also
detailed (Khorasani and Yazdi 2017).
At present, various processes are applied where materials are removed with the help of
various processes. This helps in obtaining the final part. The milling machines denotes to the tools
that are designed for solid materials, woods and metals. Very often there milling machines are
automated. These are positioned in different horizontal and vertical orientation for carving out
materials in the basis of pre-existing designs (Wan et al. 2017). Here, the designs are commonly
CAD directed. There are various milling machines that are also CNC operated through
conventionally and manually automated milling devices that are also popular. They are also able to
perform, dynamic movement for work piece and tools. They can also undertake different types of
multi-axis machining. Due to different variation of application, operation and orientation, the milling
machines consists of various functions and numerous principles of operations. As far as tooling is
concerned, the milling machine are outfitted with various heads of tools. This is done to accomplish
various needs of machining. Here, few tools include ball end mills, fluted mills, rounding mills and
cutters. Furthermore, few milling machines have consisted of ends of rotating tools changing the

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dependences in the required activities. Here, the communications with computer programming with
machine are done as there is any change in the tooling.
Various tools used in milling machines are on the basis of intended and material shapes. Due
to the fact that materials such as steel and woods consists of various physical characteristics, the tool
bits are required to be machine those metals properly. As the machine of milling utilizes any tool bits
that are not strong enough for machine steel, the tooling and machines itself also undergoes
damages. This is also strong for soft materials damaging the work-pieces (Stephenson and Agapiou
2016). Here, the primary tooling bit over milling machines are known as cutters. It refers to a shaped
bar consisting saw teeth. This rotates very fast for cutting down and shaping materials. This is
attached to arbors and is known as madel. This includes a shape bar varying in ending, length and
size and used to hold the cutters strongly. A saw ending of millings are oriented, sized and shaped in
various ways. These teeth are located in various orientations in straight up and down manner.
Besides, it is angled in helical orientations and the straight teeth are preferable in operations over
denser materials as the helical teeth creates smooth cuts over soft materials (Sun et al. 2016).
Further, there are various cutters at these categories. This includes t-clot cutters, angle cutters and
dense end cutters. These are subjected to various standard sizes having CAT sizes as the
commonly0utilizwed standardizations categories. As mechanical modelling is a vital feature of this
process of engineering, the review is concentrated of various diffusion, isotherm and kinetic models.
3. Conducting of literature review:
3.1. The process of milling:
It is versatile part of machining processes. This removal of metal is dine through relative
motions of multi-axis, multi-edge cutter, motions of rotating movements of work-pieces. It is a form
of interrupting cutting. Here various repeated cycles of exit and entry motions of those cutting tools

7METAL REMOVAL TECHNOLOGY
has been accomplishing the actual removal of metals with discontinuous generation of chip. Xiao et
al. (2016) mentioned that The milling comprises of variations of machine work-pieces, tooling and
machine types that any other type of machining method. These milling machines coming from
models of tabletops ate the standard vehicle knee mills. They have been operating in similar
principles and parameters of operations. The most vital part of those operating parameters includes
various aspects. The cutting speed is included here which is the speed at which tools has engaged
with the task. Further, it includes feed rates. This includes where the distance tool edge has been
travelling in cuter revolution. Moreover, there is axial depth of cutting. It represents the tools to set
below of machined surfaced. Here, radial depth of cut where the quantity of work surface has been
engaged by that tool. Moreover, the abilities of milling machines are calculated by spindle taper size,
maximum spindle speeds and motor horsepower.
3.2. Basic of milling machines:
The primary milling machine includes vertical spindle, ram-type “knee” mill. However, it is
adapted well for producing milling. This is ideal of making tools and machining prototypes.
Moreover, the knee mills are mainly used for various manual operations. However, Zhou et al.
(2018) argues that these abilities can also expanded. The knee has been travelling vertically, up and
down the columns and supporting table and saddles. Here the saddle has been moving out and in
from column, where table has been moving side by side of that columns. Apart from this, the ram, at
top of that column has been supporting milling head that contains feed controls, speed, tool heads
and motors, spindle and quills. This non-rotating quill has been holding rotating spindles. Here, ram
can be removed from both in and out from that columns and is tilted for drilling and angular milling.
The cutting of tools are secured in collecting and drilling chucks that are held in that spindle. Here,
works are commonly protected to tables through using clamps and bolts through using fixtures and
vises that ate bolted to tables. This work table has containing longitudinal “T” slots for facilitating

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the attachments of those devices. The abilities of knee mills are expanded through using digital
readout displays and technologies (Wu and Zhang 2014).
3.3. Reducing milling trips and time with milling cutting edges:
The engineers has used pressed sintered carbide of tungsten. These AMT cutters are available
in various metallurgies and shapes. This broad range of cutter has inserted metallurgical and profile
choices. This has been enabling higher flexibilities in designing mills. Here cutting structures
consists of particular properties of performances (Jozić, Bajić and Celent 2015). This is applicable to
base of various applications and tasks. Thus depending on that applications, milling tools have been
including various kinds of AMT cutters for optimizing different aspects of milling operations. These
cutters are designed for taking mills to toughest steels. This includes nickel-content materials and
high-chromes.
3.4. Advanced milling with developed cutting edges and structure:
Then there are cutting structures including cutters that has comprised of developed wear
rates, cutting edges, and impact resistances that has been resulting in shortened milling time. Next,
they are able to withstand abrasive and exotic materials are common to fishing and milling
operations, reducing the time and maximizing performances in broad range of deployments as shown
by Han et al. (2016). This cutters has been sharping profiles with chip-breaking features for
controlling cutting sizes and shapes, enabling efficient cutting removing and management of debris.
3.5. Types of Milling Machines
The machines of milling are differentiated as per orientation to work-pieces and degree of motions.
The first one is knee-type. This a vertical workspace that is been supported by knee. This is an
adjustable vertical casting. This knee supports the saddle and adjusted to allow regarding
customizable workspaces. Then there are plain horizontal and vertical tools. These with standard

9METAL REMOVAL TECHNOLOGY
work surfaces are oriented horizontally or vertically. This assembly of tooling is affixed on swivel
and turrets and is positioned parallel to workspaces. This swivel and turret has been allowing the
tools to move freely across work-pieces for enforcing tight kind of tolerances. Then there are
universal horizontal machines of millings as per Canakci and Varol (2015). This differ from plain
horizontal kinds since this is a table swivel housing. This is helpful to move the table in 45 degrees
from the standard horizontal location. This movement of work-piece permits to gain easy angular or
helical operations of milling. Then there are ram type and milling machines. This are also universal
in many cases. It is helpful to allow tooling for positioning them over higher ranges of spaces as the
work pieces. This ram-type machines consist of spindles over movable housings that can move
under any set of horizontal plane. It is a universal ram-type milling machine that involves swivel
housing rising the range of cutting movements. Next, there is swivel cutter head which is a ram-type
milling system. Several cutters with milling machines are able to rotate from a totally vertical to
horizontal position. This workable has been moving and providing the users with liberal degree of
orientation and motion. Various swivel cutters has included hand driven and automatic settings and
rise in options of operations.
According to Al-Sandooq, Yousif and Jensen (2015) the milling is a primary drilling taking
place among various powered processes of metal cutting. It is versatile for basic processes of
machining. However since the milling set up comprises of various degrees of freedom. This milling
is less accurate regarding or turning irrespective of rigid featuring is deployed. There are also manual
machining and is important to fabricate objects that are not symmetric axially. Moreover, there are
broad scopes of various milling machines. This ranges from manual light-duty Bridge-ports. Various
CNC machines regarding milling are consisted of hundreds of feet longs. For example, Cao, Zhou
and Chen (2015) analyzes that organizations such as Sinotech has been offering exceptionally wide
range of secondary procedures applied to metals that are formed in cold or hot processes. Their

10METAL REMOVAL TECHNOLOGY
quality engineers has been finding the availability of processes under metals forming facilities and
quality. As the internal secondary process never meet standards of Sinotech, then the process is done
under Sinotech-audited and qualified facilities of secondary processing. Karagüzel (2015) mentioned
that it has worked, qualified and audited with QS-9000 and various ISO certified secondary
procedures that has been facilitating various nations for many years. It is dedicated to control the
project on-sites and delivering various parts at lower process with same quality, service and terms as
domestic suppliers.
3.6. Problem statement:
As per Maher, Sadeghi and Moheb (2014) the milling is the process to eradicate metals
through feeding tasks against cutters with rotating multipoint. The surface gained by machine tool is
greater in quality and more precise and accurate. Here, the metals ate eradicated through faster rates
as the cutters het various cutting edges and rotating with high speeds. It is also possible to perform
the machine g through mounting more than a single cutter at any instance of time. This table of
machine is moved through accuracy of 0.02 mm. It is also helpful as different cutters and precise
tools are machined. Various special attachments ate mounted on machines for performing operations
done in additional machine tools. However, tyere are various challenges in this section also.
 This cost of milling machine has been high.
 Since the cost of milling cutters are high, investments to procure the tools are more.
 Production cost rises as one carries out operations that are done with specific shape or
drilling machine with milling machines.

11METAL REMOVAL TECHNOLOGY
3.7. Milling operations:
As the process cycle goes on, various operations are done to work-pieces for yielding
intended part shapes. These operations are done with defined kinds of cutters used and oath of
cutters for eradicating metals from work-pieces.
The end-milling indicates making peripheral and slot cuts. This is done through step-over
distances around work pieces for machine specific elements. This includes complicated surface
contour, pockets, slots and profiles according to Machida and Horizoe (2015). Here the depth of the
element is machine in a pass and is reached by machining at least axial depth of cutting and creating
various passes.
Next, there are end milling activities or pocket millings. The first one is chamfer milling.
This makes peripheral cut across edges of work pieces and featuring to develop angles surfaces that
are identified as chamfers. This a typical 45 degree angle and is machines on interior or exterior of
parts and follows curved and straight paths. Next, there is chamfer milling activities. This face mill
machines are flat surfaces of work-pieces for providing smooth finishes. Here the depth of the face is
little and is machines in one pass and is reached through machining smaller axial depth of cutting
and creating numerous passes. Next Luo, et al. (2015) analyzes that there is face milling tasks. Then
there is drilling. This enters the work-pieces in axial manner and cutting hole with diameters that are
same as the tool. This task of drilling is able to create blind holes that extends to some depth within
the work pieces and through holes extending totally through work pieces. Then there is drilling
operations. Here the boring took enter work pieces in axial way and cuts along internal surfaced
forming various features. This is single-point tool of cutting and is set to cut the intended diameter
through using boring heads that are adjustable. This is totally done as drilling the hole for enlarging
diameters and obtaining precise dimensions. Then Lu et al. (2016) discusses that there is the boring

12METAL REMOVAL TECHNOLOGY
operation. This counter bore tools gets access to work pieces axially and enlarges the highest part of
the current hole to the tool’s diameter. The counter boring is done as the drilling is done for space for
heading of fasteners. This includes bolts o sitting below the part of the surfaces. This counter boring
tools consists of pilot to end for guiding that straight forward to the current hole.
Next there is counter boring activities. The first one is counterstriking. This tool enter the
work piece in axial way and extends the top part of the current hole that has a cone-shaped opening.
This counterstriking is done as the drilling is done to provide space for the head of fastener like
screw and sitting flush with work piece surfaces. Here, the common angles include various degrees
as per Komkiene and Baltrenaite (2016).
3.8. Taping operations:
The milling machines are found over various designs and sizes and has been still possessing
similar elements enabling work pieces to be moved in various dimensions that are relative to the
tool. These elements includes various factors. The first one is base and column. Here the base of the
machine is put in the platform sitting over the ground and supporting machines. This column is
attached to the base and connecting to various components. Next there is the table as stated by
Hebbar et al. (2016). This work piece is milled to be mounted of platforms known as table. This is
“T” shaped along the surface. This work price id secured with fixtures known as vises and is secured
with T slots and work pieces clamped to those slots directly. This table provided horizontal paths of
work pieces in various X directions through sliding across platforms below that known as saddle.
This is the platform supporting table and allowing longitudinal motions. Golik, Komashchenko and
Morkun (2015) mentions that this is also able to provide and move in horizontal motion of the work
piece in Y direction through sliding in transverse manner as per another platform known a knee. This
is the platform supporting table and saddles. Here most of the milling machines known as columns

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and knee milling machines has been providing vertical motions of that elements of works. This knee
can move in vertical manner around the column and moving work pieces in vertical ways as the
cutter stays stationary above that. However, under limited bed machine, this knee is fixed and the
cutter mover in vertical path for cutting the work piece.
3.9. Manual vertical milling machine:
These elements of milling machine are oriented horizontally and vertically. Thus they have
developed two different types of milling machines. This horizontal machine utilizes cutters mounted
over horizontal shaft, known as arbor, above work pieces. Due to this cause horizontal milling is also
known as arbor milling. This is supported over one side by overarm. This is interconnected to the
column and other side of the spindle as per Fischer et al. (2015). It is driven through motors and thus
rotated those arbors. As milling takes place, the cutter rotates across the horizontal axis and side of
that cutter eradicates materials from worm pieces. This vertical milling machines has been orienting
the cutters in vertical way. This cutter is safe within element known as collet. This is attached over
vertically oriented spindles. It is situated within the milling head known as column. These activities
are done over vertical milling machines eradicating materials through sides and bottom of the cutter.
Apart from this, the milling machines are categorized to various kinds of controls that are
utilized. This manual milling machine needs operations of controlling the motion of cutter. This take
place as the milling activities goes on. This operator has been adjusting position of cutters through
hand cracks moving knee, saddle and tables. Thee milling machines are able o be controlled through
computers. This is case they are denoted as CMC or Computer Numerical Control with milling
machines. According to Zou et al. (2016) these CNC milling machines has been moving work pieces
and various cutters in the basis of commands that are been preprogrammed and offering huge
precision. These programs are documented to NC-codes and G-codes. Here, the CNC milling

14METAL REMOVAL TECHNOLOGY
machines are also contain another axis of motions apart from X-YZ motions. Here the various angles
of milling machines also gets changed helping various complicated shaped to be milled.
3.10. Tooling in milling:
This is needed for milling as the sharp cutters rotating across the spindles. Here, the cutters
are cylindrical tools having sharp teeth spaced across exterior. These spaces has been taking place
between flutes and allowing material chips for moving apart from elements of works. Thee teeth is
straight across the side of cutters. However, they are been arranged commonly in helix. This helix
angles has been loading the teeth through distributing the forces. Moreover, Prucek discusses that
(2015) there are various teeth over cutter varies. Then there are huge number of teeth providing
better finishing of surfaces. These cutters are used for various operations of milling that are mostly
diverse. This has been permitting forming of various elements. These cutters has been differing
highly in length, diameter and shaping the cut that is formed. This has been differing on the basis of
orientations. This is irrespective of the fact that they are used vertically and horizontally. This cutter
has been utilized under horizontal milling machine that has the teeth extended across the complete
length of that tool. This interior of the tools has been hollowing such that it is counted to the arbor.
This is the primary form that there are still various kinds of cutters used in horizontal milling.
This also includes plane or helical form relived and staggered tooth and double angle mills. In this
research the Taguchi method is selected. Under the domain of metal removal, the parametric
optimizations, central themes are used for Taguchi method. Besides, there is a rise in interest of
optimizations as competitive tools towards sustained manufacturing. Besides, Machida and Horizoe
(2015)writes that it is also proved that the problem gained through developed results of
optimizations are addressed in urgent way. This is under the perception of rising harsh environment
of business. The partnering of Taguchi Method and simplex algorithms has promised developed

15METAL REMOVAL TECHNOLOGY
results of optimizations resulting and pursued benefits of metal removing processes across the world.
Studies if optimizations to create and deploy methods for predicting optimal value parameters in
mind are the factors such as costs, lead times and productions rates. This also include an energy
effective problem.
Various metal manufacturing processes:
Casting processes These processes of meal casting has involved pouring molten metals
to mold cavities. Here solid metals has been talking shape of cavity.
Further, Javanbakht, Alavi and Zilouei (2014) discusses that they are
distinguished to two parts on the basis of type of mold. There are
expendable mold castings where molds are destroyed for removing
their parts. Then there are permanent mold casting where molds gets
fabricated out of ductile materials is used repeatedly. Next, there is
powder metallurgy where metal powders are compacted to intended
shapes and heated for causing particles of bonding to rigid masses.
Deformation processes These deformation processes has included metal forming and
processes of metalworking sheets. They have used plastic
deformations that have resulted to use tools that are applicable to
stresses for the piece that exceeds yields of stress of metals. Here,
Farha (2015) highlights that there are two kinds of processes of
deformations. The first one is bulk processes. This is characterized
through huge deformation and changes in shape. This by fact
includes surface areas to volume rations that is relatively small. This

16METAL REMOVAL TECHNOLOGY
bulk processes has included bar drawing, wires, extrusions, forging
and rolling. Then there is sheet metalworking processes is performed
on coils, strips and metal sheets having huge area of surfaces for
volume ratios. Here, the operations has used punches and dies from
work pieces. shearing, drawing and bending are kinds of sheets of
metalworking process.
Metal removing
processes
The processes has eradicated additional materials from work-pieces
foe achieving intended shapes. Then there are machining operations.
These are cutting operations through cutting tools that has harder
than metal of that product. This has included sawing, broaching,
planning, shaping, milling, drilling and turning. Next, there is
abrasive machining as per Howarth et al. (2015). Here these materials
are eradicated through abrasive particles that forms bonded wheels.
Then there is nontraditional processes. Here the methods has used
electrochemical energies, chemical erosions, electron beams and
lasers. This is used instead of grinding tools and conventional
cuttings.
Assembly and joining
processes
There are various parts in this assembly and joining process. This is
connected semi-permanently and permanently for forming new
entities.
3.11. Meeting strict regulations and promoting environmental stewardships:
This is done through eradicating heavy metals from various streams of wastewaters. The
industrial processes are able to release heavy metals to wastewater streams. This results in potential

17METAL REMOVAL TECHNOLOGY
contamination of the current environment. Thus various regulating agencies has needed heavy metal
removals originating from wastewaters. This happens before they gets discharged to nature. Various
regulatory necessities are to be met on wastewater effluent limits. They have been driving
compliances to the goals of environmental stewardships. Moreover, Al-Qodah and Al-Shannag
(2017) demonstrates that heavy metals are to be removed over wide range of pH ranges. Then there
is usage of chemical solutions in order to particulate various heavy metals like zinc, nickel, mercury,
manganese, iron, chromium, copper and lead. Then there is removing of selenium with various
advanced kinds of biological treatments.
3.12. Reducing overall selenium to various low single-digit ppb levels with one step process:
The ABMet process of SUEZ helps customer ion FGD, mining and various other sectors for
emerging strict selenium discharge limits in just one step. This is done with minimal operating costs
and attentions of operators. Besides, Ahmed et al. (2017) mentions that ABMet has been removing
metals and nitrate including arsenic and mercury. Innovative seed culture with particularly
formulated nutrient and design of bio-filter provides time seeding, reliable performances and quick
setup.
ABMet for
FGD
wastewater
This proven solution has been constantly meeting discharge limits in EPA
as proposed by ELG for wastewaters of FGD. Then there is effective nitrate
removal as per Fischer et al. (2015). Further, there is effective mercury and
polishing arsenic. Moreover, there is non-hazardous waste solids that is
processed easily through physical and chemical solid systems of handling.
Then there is direct discharge instead of post and pretreatments.
ABMet for
mining waters
Then there is modular pre-fabricated designing for installation at distant
locations. Further, there is direct discharge instead of pre-treatment of post-

18METAL REMOVAL TECHNOLOGY
treatments. Then there is remote process monitoring along with the insight
platforms. Next, Habibul, Hu and Sheng (2016) shows that there is only one
consumable product. This is all-in-one nutrient product. Then there is low
volume solid wastes for hazardous disposal.
3.13. Material processing:
This series of operations has been transforming industrial materials coming from raw-
material states for finishing various products and parts. The industrial materials are been defined as
those that used in manufacturing of hard goods. Then there is less durable machines and tools
developed for consumers and industries. It has included unlike the disposal of soft goods like
apparel, pharmaceuticals, foodstuffs and chemicals. The manufacturing process cycle has been
converting materials to products and parts that have been beginning immediately as raw materials
gets extracted from minerals or produced from natural substances and basic chemicals. Then there is
metallic raw materials that created in a couple of steps. Firstly, the crude ore is created to rise the
concentration of intended metals. It is known beneficiation as shown by Kulikowska et al. (2015).
Any typical beneficiation process has involved leaching, flotation, magnetic separation, roasting,
crushing. Next, the extra processes like allowing and smelting are used for producing metals that
gets fabricated to arts that are assembled to any products.
Lu et al. (2016) mentions that at the case of ceramic materials, natural clay is the mixture
and blends of different silicates for producing raw materials. The plastic resins are created through
chemical methods in liquid, putty, powder forms. The synthetic rubbers are created of chemical
techniques, produced and natural rubbers in the form of foam, crepe, sheets, slab to fabricate
finished parts. Here, processes used for converting raw materials to various finished products has
been performing various primary functions. Firstly, they have been forming materials to intended

19METAL REMOVAL TECHNOLOGY
shapes and altering and improving properties of materials. The shaping and forming processes are
categorized in various broad types. These are done on materials at liquid states and performed over
materials in plastic and solid conditions. This processing of materials in liquid format is referred to
as casting as it includes metals, ceramics and glasses. This is known as molding as applied to plastics
and nonmetallic materials. Besides, molding processes and casting has included 4 important steps.
This includes removal of hardened part from the mold, introducing liquids to molds, creating mold
from patterns and creating suitable patterns of that part. The materials present in solid states are been
formed to intended shapes. This is done through applying pressure and force. This material that has
to be processed is relatively complex and in stable condition. This is in the form of powders, pellets,
sheets and bars.
Otherwise this is soft, puttylike and plastic in nature as shown by Machida and Horizoe
(2015). Various solid materials are shaped cold and hot. The metal processing in solid state is
divided two primary stages. The first one is the raw material in the format of huge billers or ingots
that is hot-worked. This is done through rolling, extrusion, forging to smaller shapes and sizes.
Secondly, the shapes gets processes to ultimate products and parts through various smaller scale of
cold and hot forming processes. As the materials get formed, this can get changed. Here, in material
processing, processes are removed that can eradicate portions of body or piece of materials that are
achieved through desired shapes. Further, Cao, Zhou and Chen (2015) mentioned that removing
process are applicable to various kinds of materials. They are not used widely to different, metallic
materials. This can be eradicated from work-pieces through non-mechanical and mechanical issues.
Moreover, there are various types of metal-cutting processes. Here machining has included force to
cut tools against various materials that are to be shaped. Here, the tool is complicated than the
material that has to be cut. This helps in removing various unwanted materials in the format of chips.
In this way the elements of machining are the cutting devices. This indicates the positioning and

20METAL REMOVAL TECHNOLOGY
holding of work-pieces and lubricating in nature. Here, four primary non-cutting removal processes
are there. This includes chemical milling metals that is removed through etching reactions of various
chemical solutions over those metals. This is applicable to metals that is used over glasses and
plastics. Then there is electrochemical matching using principles of metal plating as per reverse
mode.
This is done instead of being created of plating processes that is eaten away in controlled
manners through actions of electrical currents. Further, the electro-discharge grinding and machine
has been eroding and cutting metals through high-energy sparks and electrical discharges. Then there
is laser machining cuts over refractory and metallic materials having intense beam of lights coming
from lasers. Then there is changes of joining, processes of permanently and at many time
temporarily, attaching and bonding materials to others as highlighted by Canakci and Varol (2015).
Here, the terms used here has included chemical bonding, adhesive, soldering, brazing and welding.
At the joining processes, bonds between various pieces of materials are created through applying of
assimilation of various types of energy, mechanical, chemical and thermal. This filler and bonding
materials, that has been different and same as the materials to be joined and might or might not be
utilized. These characteristics of materials can be changes through cold and hot treatments. This is
dine through mechanical operations and exposure to various types of radiations. Here, property
modifications are brought though changes in microscopic structures of material.
Here, Wu and Zhang (2014) demonstrated that heat-treating has involved temperatures above
room temperatures and cold-treating that has included temperatures below room temperature that is
involved in category. Here, thermal treatment is the process where temperature of materials is raised
or lowered to modify the characteristics of original materials. Maximum of thermal-treating
processes are been on the basis of cycles of time-temperatures. This involves three steps. This

21METAL REMOVAL TECHNOLOGY
includes cooling, holding temperature and heating. However, there are thermal treatments that is
applicable to most of families of metals. This are most widely used over metals. At last, the
processes of completion is employed for changing the material surfaces for securing material against
detoriations through deformations, mechanical wears, oxidations, corrosions for providing particular
surface characteristics. This includes bearing properties, insulations, electrical conductivities and
reflectivity. Al-Sandooq, Yousif and Jensen (2015) analyzed that this is to provide particular surface
properties like insulations, electrical conductivity, reflectivity and bearing properties. They have
been providing materials with particular decorative impacts. Here, there are two wide teams to finish
processes, where coating is done with different materials. This is applicable to surfaces and those
where the surfaces of materials that is modified through chemical actions. Here, the initial team
involves metallic coating, like porcelain enameling, painting, organic finishing, electroplating.
4. Methods of milling for the research:
Milling is referred to as the most versatile among all types of machining processes. Here,
removal of metal is done through different relative motions of rotating, multi-axis movements and
multi-edge cutters of work pieces. It is a kind of interrupted cutting. Here repeated cycles of various
motions of entry and exit of cutting tools are done as per the real metal removal. This also includes
discontinuous generation. It consists of different variations in work-piece, tooling and type of
movements that any kind of machining methods (Jozić, Bajić and Celent 2015). Every milling
machines from various tabletop models or standard knee mulls or huge CNC machining centers has
been operating on similar guidelines and operating parameters. Here most crucial of those
parameters are the cutting seeds. This is the speed at which tool engages the work. Then there is feed
rates that denotes distance of tool edges in a single cutter rotation. Next is the axial depth of cut
where the distance of the tool is been set below machines surfaces. Besides, the radial depth of cut is

22METAL REMOVAL TECHNOLOGY
the quantity of work surface that is been engaged by the tool. Here the abilities of milling machines
are calculated through spindle taper size, maximum spindle speeds and motor horsepower (Cao,
Zhou and Chen 2015).
Here the Taguchi method is to be conducted. This technique has explored the idea of loss
functions of quadratic quality and using statistical performance measurements known as S/N of
Signal to Noise ratio. This denotes to the ratio of signal or mean to noise of standard deviation.
Here, the ratio has been depending on quality characteristics of processes and products to be
optimized. This optimal setting is the parameter combination that has the largest S/N ratio (Wu and
Zhang 2014). On the basis of S/N or signal-to-noise assessments, the S/N or signal-to-noise ratio for
every stages of processes parameters are calculated (Jozić, Bajić and Celent (2015). Higher value of
S/N ratio has corresponding to effective performance characteristics irrespective of performance of
category. This indicates the process level parameters consists of greatest S/N ratio corresponding to
optimum process levels of parameters. At last the confirmatory analysis is done to verify the optimal
processing parameters that is obtained from parameter design.
5. Experimentation:
In this research primary data analysis is done through calculating various results obtained
from Taguchi’s theory. First of all the cutting parameters are to be selected. Here dimensional
accuracy and surface quality are the vital aspects of products in various operations. Various factors
has been influencing ultimate surface roughness under CNC milling activities. This theoretical
surface roughness has been dependent commonly on various different parameters. This includes too
geometries such as run-out errors, tool noise radius and various flank width. The n there are work
materials, different cutting conditions and machine-tool rigidity. This includes depth of cutting
speeds and feed rates. Apart from this different considerations like material properties, chip

23METAL REMOVAL TECHNOLOGY
formations and chip loads and tool wears. These are the work pieces that are uncontrollable as real
machining take place. Further, the presence of vibration chatters of machine tools and issues in
surface work materials wear in irregularities and tools of forming chips has contributes to surface
damage in practices as the real machining activities take place. However, it must be reminded that it
is complicated to consider every factors affecting surface finish.
Then there is the selection of response variables. The experiment must be concentrating on
various center line average value of roughness regarding surface quality. However, considerations
are not enough for describing the surface quality of multi scale rough surfaces. Here four parameters
of roughness are considered. They are center line average roughness, root mean square roughness,
kurtosis and main line peak spacing.
5.1. Work piece materials used:
Here, the medium leaded brass of UNS C34000 is used. All the specimens of mechanical
properties and chemical compositions are in the form of 100 mm*70 mm*25 mm blocks.
Here the cutting tool utilized are the coated carbide tools that are found to do better than the
uncoated carbide tools. These tools are also utilized as the mill cutters and flat and that are created
through WIDIA or EM-TiAIN. These tools ate also to be coated with the TiAIN coating. Here, for
all materials new cutters of similar type of specifications to be used. These details of cutters of end
milling includes the following.
Cutter diameter 7 mm
Overall length 105 mm
Fluted length 38 mm
Helix angle 32
Hardness 1560 HV

24METAL REMOVAL TECHNOLOGY
Density 15 g/cc and
Transverse rupture strength 3600 N/mm square
5.2. Design of experiment (DOE):
The techniques of designs of experiments has been allowing to carry analysis and modeling
of influence on process variables. These are also known as design factors on response to different
variables. Here the depth of study of cut, speed of spindles and feed rates are opted to design factors
as the other parameters are through to be consistent over present experimental domain.
Here these design factors and process variables are values over various levels and are limited
by the ability for the machine utilized in experimentation and recommended specifications for
various work prices and tools of material assimilations. Further, the five levels comprising of equal
spacing under the operating range of parameters are selected for every factors. At the current
research orthogonal arrays design is taken for analysis. Here the effect of interactions of different
process parameters re negligible.
5.3. Equipment used:
Here, the machines for milling test is are “DYNA V4·5’ CNC end milling” comprising of
machine consisting of control system of “SINUMERIK 802 D” along with a head of vertical milling.
Here, this compressed coolant servo-cut is utilized for cutting areas. In order to create milled
surfaces, CNC programs for various paths of tools are generated with particular commands.
5.4. Data analysis:
It is seen that experimental data about various features of bead geometry as per orthogonal
array or OA design of experiments are explored. This is to measure utility values of distinct quality

25METAL REMOVAL TECHNOLOGY
attributes through the help of various equations. Here for every surface roughness parameters the LB
or Lower-the-Better criterion can be used. Here, for every roughness of the parameters, most of the
entries are considered to be of acceptable value. On the other hand, minimum value that is observed
here is sees as the desired or best value. The reason is that due to every surface roughness
characteristics the LB or Lower-the-Better criteria can be used. Here the main aim is to develop
finishing of surface. This indicates that every kinds of values of roughness are lesser as possible.
The common trends in the solution of various multi-objective problems are optimization is
the change the multi-objectives initially to equivalent objective function. Through deriving the
equivalent objective function, various priority weightages are been assigned to various responses.
This is done as per the importance. However, no particular principles are available to assign the
weightage of responses. This has been totally depending on the makers of decisions. This can be
human judgment or individual perception. This is the reason why the current research has assumed
the priority weightage to every reactions. It is seen that as the Taguchi analysis is done once any
optimal setting can be predicted. The above Taguchi process has provided the predicted value of S/N
ratio of different objective functions at the optimal setting. Experiments on the other hand is done at
intended optimal setting. Here the results obtained are assimilated for measuring the overall utility
degree and as per the S/N ratio. Next, two of the outcomes are compared. The S/N ratio retrieved
experimentally is equal to more than that has been predicted. Since the S/N ratio is maximized, it
indicates the least loss in quality.
6. The current progresses:
Milling as a basic process is regarded as the most widely utilized process of metal removal.
This is used in industries and milled surfaces that are highly used for mating other parts machinery
automotive, machinery, aerospace, die designing and manufacturing sectors. Here the mechanisms

26METAL REMOVAL TECHNOLOGY
beyond this forming of surface roughness is process dependent, complex and dynamic. Hence is the
complicated to measure the value with the help of theoretical analysis. Thus the machine operators
has been utilizing the trial and error method for setting-up milling machine conditions of cutting.
This is to gain the expected roughness of the surface. However, it has been not an empirical and
repetitive method that has been much more time consuming. This widespread usage and dynamic
nature of milling has raised the necessity to seek systematic approach. This helps in set up milling
activities in time.
Moreover this also helps in achieving expected quality of different surface roughness. This
prediction of various chatter vibrations that are done between work piece and cutters are vital
principle to machine tool users for optimal selection of spindle rotation and depth of cut. This results
in most of the chip removal rate instead of having an intended outcome. It is done through various
approaches. Here, the method of analytics is done for time varying directional dynamic milling
forces of coefficients. This are further expanded in Fourier series and then integrated in width of cut
bound through various angles of exit and entry. These contact zone forces are done between work-
pieces and cutters as the cuts are analyzed through algorithms of mathematical model. This is
derived from various experimental tests with dynamometer situated between machine table and
work-piece. Here, the results of algorithm has been depending on physical properties of materials of
work-piece and different cutter geometry. Here different modal parameters of machine-work piece-
tool system such as residues, damping and frequencies are also experimentally determined. Here, it
has been possible to plot those stability lobes for the dynamic system. Here, the curves are related to
spindle speeds having axial depth of cutting, separating stable and unstable sectors. It has been
permitting the selecting of various parameters of cutting that has resulted most of the productivities.
Furthermore, the current experiments has been facing milling tests that are done in knee-type

27METAL REMOVAL TECHNOLOGY
machines. This is done through five inserts cutters. Thus the outcomes has highlighted suitable
agreements taking place between chatter prediction and tests of experiments.
On the other hand, principles of Taguchi methods are aided to select optimal process and
product parameters. It has been facilitating objectives of Taguchi off like quality controls that is
regarded to be an efficient approach to develop high quality products at low costs. The above study
has stressed and made it clear that the underpinning conceptual frameworks of methods regarding
process robustness and quality improvements. Here, the primary aim of the research is to develop
designs hat are robust and comprising of uncontrollable elements and achieving intended target
values with minimum variability. These performance measures like signal to noise ratio are also
utilized. Here, costs are the fundamental considerations for present day Taguchi method. This
includes the concept to gain the best possible designing at the least possible cost. Here, the role of
Taguchi to create and implement ideas of quality engineering are vital and constant to be pivotal in
various types of quality developments. Here the study has shown a systematic approach to carry out
the industrial experiments for manufacturing industry and service industries in the basis of Taguchi’s
process of optimization. Deploying Taguchi method of optimization is helpful to decrease the
product and process variation. This also minimizes the impacts to use comparatively small quantity
of experimental runs and minimizing the expenses to gain the most effective quality of products.
7. Timeline of the current project:
The following experimentation through Taguchi method is illustrated hereafter.
Task Name Duration Start Finish Predecessors
CNC milling 31 wks Mon
6/10/19
Fri
1/10/20

28METAL REMOVAL TECHNOLOGY
Finding control
parameter: feed
rates, spindle feed,
depth of cut
70 wks Mon
1/13/20
Fri
5/14/21
1
Taguchi designing
through 3 Levels of
controlled
parameters
32 wks Sun
6/26/22
Fri
2/17/23
2
Experimental
techniques
40 wks Mon
2/20/23
Fri
11/24/23
3
Analyzing
outcomes
35 wks Mon
11/27/23
Fri
7/26/24
4
Finding of material
removal rates
36 wks Mon
7/29/24
Fri 4/4/25 5
Determining
roughness of
surface
30 wks Mon
4/7/25
Fri
10/31/25
6

29METAL REMOVAL TECHNOLOGY
Figure 1: “Conducting the current process of milling through Taguchi method”
(Source: Created by Author)
8. Conclusion:
Here the studies that are reported has focused on center line average roughness value of
service quality. Moreover, it is also seen that considering the core line average roughness has not be
sufficient to demonstrate the quality of surface. The above roughness parameters described such a
kurtosis, mean line peak spacing is to be taken care off and must be included in the study. This
research has considered aforesaid numerous surface roughness properties regarding minimization or
optimization to be done simultaneously regarding various roughness characteristics under
experimental domains. Hence various conclusions can be drawn from the outcomes of the analysis
and experiments of experimental data. This is done in connection with different types of multi-
response optimizations in milling activities. Thus the utility based method of Taguchi is seen to be
fruitful to evaluate optimum settings of parameters. Moreover, confirmatory tests are validated to

30METAL REMOVAL TECHNOLOGY
parametric setting that is found though utility based proves of Taguchi. This method is suggested for
constant improvement in quality and off-line control of quality of products and processes.

31METAL REMOVAL TECHNOLOGY
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