Tool Geometry Optimization of a Ball End Mill based on Finite Element Simulation of Machining the Tool Steel-AISI H13 using Grey Relational Method

Materials with high hardness are usually difficult to machine, and accomplishing precise and economical machining depends on all the cutting conditions. Appropriate tool geometry is one important aspect for the cutting process that can be optimized based on the machining parameters. In this study, the finite element simulation method was applied to analyze the effects of tool geometry on the cutting forces and tool temperature during the ball end milling of tool steel (AISI H13). Multi-objective optimization of the geometrical parameters was performed using the grey relational method, which gave a set of input parameters to obtain the minimum cutting forces and temperature. The findings of this work could be used as a basis for tool design. Experiments were conducted with mono-objective and multi-objective optimal geometries to validate the finite element analysis. The finite element and experimental results were both congruous with an error limit of 5%.