Evaluation of Cutting-Edge Radius (CER) for Surface and Vibration Performance in Milling DAC Material

Tan, Jia Yi (2019) Evaluation of Cutting-Edge Radius (CER) for Surface and Vibration Performance in Milling DAC Material. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

HPMT company has launched a heavy range of product specifications for each type of cutting tools to meet the demands of customers. The company wish to reduce the product range by designing a new cutting tools with cutting edge radius (CER) in mono-designed to cater from soft to hard materials. By reducing the product range, the company is able to save costs by reducing the types of cutting tools currently producing and reduce the stocks of various kind of cutting tools. The literature review will cover the essential knowledge or information related to the objective of the project. The essential areas are end milling, design of end mill, cutting tool geometry, surface performance, methods of measurement, the information of material used in project, design of experiment and journal reviewed. The experiment will be performed by using end milling technique and using the cutting tool with cutting edge radius of 20μm,40μm and 60μm. The cutting speed and feed rate are 4000rpm and 600mm/t. Cutting depth is 6mm and cutting width range is 0.1mm to 1.2mm. The results of the experiment are evaluated and further analysed with the help of Design Expert Software. The cutting tool with cutting edge radius of 60μm is rejected as the cutting tool encounter breakage during the process. The surface roughness obtained is within the acceptable range (6.3μm to 0.8μm) and the vibration caused during the process does not produce chatter on the material surface. A few recommendations are suggested to improve the qualities and results of the experiment as the experiment results obtained are preliminary. Recommendations suggested are changing the cutting speed, feed rate, cutting depth, cutting condition and add coating on the cutting tools.