Empirical modeling of profile roughness parameters during end milling of aluminium alloy 5052/tungsten carbide/graphite hybrid composite

Abstract This study presents an empirical modeling approach to reveal the effect of end milling parameters on the profile roughness parameters. Aluminium hybrid composite was melt‐stir die cast into the required work material, setting a predetermined weight fraction of reinforcements. The experimental design was adopted using the Taguchi meta‐heuristic algorithm for the selection of the levels of the end milling parameters. The profile roughness parameters namely arithmetic average roughness (R a ), root mean square roughness (R q ), and mean roughness depth (R z ) were considered as output responses, which were measured using stylus type surface roughness tester. Non‐linear second‐order empirical models were formulated and from them, the profile response parameters were predicted with 95 % accuracy. The results revealed that the depth of cut and spindle speed are contributing 54.22 % and 38.6 % respectively among the selected input parameters on the cumulative output.