An end-milling condition decision support system using data-mining for difficult-to-cut materials

We proposed the data-mining methods using hierarchical and non-hierarchical clustering methods to help engineers decide appropriate end-milling conditions. The aim of our research is to construct a system that uses clustering techniques and tool catalog data to support the decision of end-milling conditions for difficult-to-cut materials. We used variable cluster analysis and the K-means method to find tool shape parameters that had a linear relationship with the end-milling conditions listed in the catalog. We used the response surface method and significant tool shape parameters obtained by clustering to derive end-milling condition. Milling experiments using a square end mill under two sets of end-milling conditions (conditions derived from the end-milling condition decision support system and conditions suggested by expert engineers) for difficult-to-cut materials (austenite stainless steel) showed that catalog mining can be used to derive guidelines for deciding end-milling conditions.