Investigation on manufacturing of small-sized stepped rotor wheel by engraving milling process

This study aims to explore the potential of the engraving milling process to manufacture 3D structures and layouts like rotor wheels. An experimental study was carried out to manufacture a stepped rotor wheel from EN8 steel blank using a computer numeric control (CNC) engraving milling machine tool. The impact of variable parameters, namely rotational speed (SR), feed (f), and plunge feed (Pf), on maximum roughness depth (Rt) and material removal rate (MRR) was determined through a total of fourteen tests, each with two replications based on Box-Behnken design (BBD) of the response surface methodology (RSM). The best variable combination was found using desirability functional analysis (DFA) with goals of minimizing Rt and maximizing the MRR. The best values achieved at the optimal combination of variable parameters were 2.95 µm as Rt and 43.45 mm³/min as MRR. Micrographs of the rotor wheel blades and cutting tool supported the findings.