Evaluation of Cutting Edge Radius (CER) For Tool Wear in Milling DAC Material.

Chu, Ming Shen (2019) Evaluation of Cutting Edge Radius (CER) For Tool Wear in Milling DAC Material. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

The cutting tool is carrying an important role in machining process especially in milling machine. During milling process, the cutting edge radius is the main contact on the material workpiece.There are many factors that can influences the cutting tool such as spindle spindle speed, cutting depth and cutting width. The cutting edge radius of tool will be easily to wear, and the tool life will become shorter. The title of this project is ‘Evaluation of cutting edge radius (CER) for tool wear in milling DAC material’. Due to the high range of product to meet the diversified condition for machining and material specification, the manufacturer is faced with a heavy product range to produce. The product range can be reduced if different cutting edge radius (CER) in a mono designed tool can be evaluate to cut a range of normal material hardness. The objective in this study is to determine the optimum cutting edge of a mono designed tool on tool performance in term of tool wear when machining on a DAC material. The cutting tool used in this experiment was uncoated end mill carbide tool. By evaluating the cutting edge of a mono designed tool on tool performance in term of tool life when machining on a DAC material, the company will save a lot of inventory cost , easy to sell the product to customer and reduce production range on designing different tool. This project helps to evaluate the cutting edge radius of a cutting tool in term of tool wear to cater the different material hardness. There were 9 experiment done for 3 type of cutting edge radius in this project which are 20, 40 and 60 μm. Dry cutting process is performed for this experiment. An analysis was carried out by using a Supereyes microscope and Design Expert after milling process. The result taken from the microscope shows all the tools were wear off fast and the flank wear value are higher than the recommended flank wear value. There are no suitable cutting edge radius suitable in machining DAC. The reluctant cutting edge radius in this experiment that could be accepted were CER 20 and CER40. Therefore, recommendation such as decreasing the cutting depth from 6mm to less than or equal 0.5mm, add cutting fluid, increase number of flute and apply coating on the cutting tool.