Experimental Optimization of Cutting Parameters in Flat-Surface End Milling Using the Taguchi–Desirability Approach

Tran Thanh Tung; Nguyen Xuan Quynh; Tran Vu Minh

doi:10.48084/etasr.18640

Authors

Tran Thanh Tung Faculty of Engineering Mechanics and Automation, VNU University of Engineering and Technology, Hanoi, Vietnam
Nguyen Xuan Quynh School of Mechanical Engineering, Hanoi University of Science and Technology, Hanoi, Vietnam
Tran Vu Minh School of Mechanical Engineering, Hanoi University of Science and Technology, Hanoi, Vietnam

Volume: 16 | Issue: 3 | Pages: 36693-36699 | June 2026 | https://doi.org/10.48084/etasr.18640

Received: 10 March 2026 | Revised: 30 March 2026 and 18 April 2026 | Accepted: 30 April 2026 | Online: 18 May 2026

Corresponding author: Tran Vu Minh

Abstract

Flat-surface end milling is extensively used in the manufacturing of mechanical components and machine elements, where both surface quality and machining efficiency are important performance indicators. However, the selection of cutting parameters often involves a trade-off between surface roughness and machining time. The optimal conditions reported in the literature are not always directly transferable to different machining systems. In this study, cutting parameters for flat-surface end milling of ALU 6061 were experimentally optimized using the Taguchi method combined with desirability analysis within a practically feasible machining domain. Milling experiments were conducted on a GMS 800 three-axis CNC machine using an 8 mm solid carbide end mill, with spindle speed and feed per tooth selected as the primary control factors. Surface roughness and machining time were evaluated for each experimental run based on an L9 orthogonal array. Signal-to-Noise Ratio (SNR) analysis showed that feed per tooth is the most influential parameter on both surface roughness and machining time, accounting for approximately 65.8% of the total effect on surface quality. Empirical regression models were established to quantify the relationships between cutting parameters and machining responses, and their adequacy was examined through residual analysis. Multi-response optimization using a desirability function identified an optimal cutting condition of 3000 rpm spindle speed and feed per tooth equal to 0.2506 mm/tooth , providing a balanced compromise between surface finish and productivity. Although the study does not propose a new optimization algorithm, it provides an experimentally validated, practically applicable guideline for selecting cutting parameters for flat-surface end milling under a specific machine–tool–workpiece configuration.

Keywords:

milling, cutting parameter optimization, surface roughness, machining time, Taguchi method

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