Use Taguchi Method for Optimization of Polyurethane Foam Surface Roughness on CNC Router Machining Process

Polyurethane modelling foams effectively replace original materials in many applications contributing to distinct comparative advantages in orthopaedic implants, packaging, and energy-efficient materials. A versatile machining method known as CNC milling was developed for processing PU foam. This technology enables the creation of complex and precise designs with high accuracy and repeatability. This experimental study examines the surface roughness of milled PU foam. The impact of parameters for machining on surface roughness was assessed. The Taguchi methodology was employed to optimise the trial design and evaluate the optimal outcomes of all quality answers concurrently. The analysis of variance (ANOVA) method was employed to identify relevant factors and quantify their contributions, thereby elucidating the importance of each aspect in the process. Post-CNC milling, evaluations of linear and areal surface roughness are compared and quantified for application in future research. Moreover, a reduction in feed speed, coupled with a rise in spindle speed and feed depth, will diminish the surface roughness value. Further surface roughness metrics have been assessed. Optimal machining parameters are attained by utilising a spindle speed of 9000 RPM, a feed rate of 500 mm/min, and a depth of cut of 0.75 mm.