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)
摘要
Optimizing the milling parameters for machining hardened Duplex 2205 stainless steel was investigated with the aim of minimizing vibration and enhancing performance. Experiments were conducted using a solid carbide four-flute end mill on a CNC vertical milling at spindle speeds ranging from 500 to 1000 rpm, feed rates from 63 to 160 mm/min, and depths of cut between 0.1 and 0.3 mm, employing response surface methodology for analysis. The optimized parameters—spindle speed of 710 rpm, feed rate of 100 mm/min, and depth of cut of 0.2 mm—resulted in a measured material removal rate (MRR) of 72.18 mm³/min and significantly reduced vibration amplitudes, with maximum velocity values in the Z-direction dropping to 137.7 mm/s. Vibration acceleration analysis revealed the lowest amplitudes at the optimized settings across all axes (minimum: 0.63 mm/s² in X-direction). The regression models yielded an R² of 0.98 for MRR prediction and above 0.99 for cutting force components. Temperature profiling showed tool temperatures remained within the range of 32.4–32.5 °C under optimized conditions. Power spectral density analysis confirmed the reduction of dominant vibrational frequencies correlating with improved tool life and surface integrity. These results demonstrate that selecting optimal cutting parameters significantly improves the machinability of Duplex 2205, with measurable performance gains in vibration control, thermal stability, and process efficiency.