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The measurement of cutting forces using highly sensitive piezoelectric force sensors is significant in the optimization of the machining process. In this study, the modelling and optimization of the cutting forces during the milling process of Ti6Al4V was carried out using the Response Surface Methodology (RSM) and the dynamometer. The ranges of the process parameters are: cutting speed (250-280 mm/min), feed per tooth (0.06-0.24 mm) and axial depth of cut (0.30-3.0 mm) are varied over four levels while cutting force serves as the response of the designed experiment. The physical experiments were carried out using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling. Three sets of 2-flute, 10 mm corner radius mills was used for the machining operation. A solid rectangular work piece of Ti6Al4V was screwed to the stationary dynamometer (KISTLER 9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) mounted directly to the machine table. Milling operations were performed using different cutting parameters of cutting speed, feed per tooth and depth of cut and data were collected through Data Acquisition (DAQ) connected to the computer. The numerical experiment produced a mathematical model for predicting the values of the cutting forces as a function of the independent process parameters while the physical experiment revealed that the piezoelectric sensor is highly sensitive to variations in the values of the cutting force.

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