A Study on Optimizing Cutting Parameters to Reduce Surface Roughness in Machining Sus316 Material

Wong, Willy Kiin Chuong (2019) A Study on Optimizing Cutting Parameters to Reduce Surface Roughness in Machining Sus316 Material. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

The surface roughness and tool vibration are the important factors which will influence the product quality. A good surface roughness can reduce the production time and cost. Surface roughness is the surface texture of a component. Furthermore, a bad surface roughness is caused by inappropriate combination of cutting parameters such as spindle speed, cutting width, feed rate, cutting edge radius and depth of cut with reference to cutting tool material during milling process. Hence, these cutting parameters should be optimized so that it can produce a better surface roughness for the work piece. In this study, 5 sets of parameters which are feed rate, spindle speed, cutting edge radius, depth of cut and width of cut were designed through the software called Design of Expert. The 5mm diameter 3 flutes uncoated carbide was used in this experiment. In order to measure the surface roughness, the SUS316 material has been used as the component to be machined. After that, CNC milling machine is used to do the milling on the SUS316 material by applying the 5 parameters. There will be three value in the parameters were fixed which are the spindle speed is fixed as 2700 rpm, feed rate is 170 mm/min and depth of cut is 4.2mm. The cutting parameters are fixed so that there are no large numbers of experiment will required. Then, another two parameters will set in a given range which the width of cut are 0.1mm, 0.6mm, 1.2mm and the cutting edge radius are 20μm, 40μm and 60μm. The response are surface roughness and tool vibration. Next, the TIME3220 surface roughness tester was used to measure the surface roughness of the work piece. The accelerometer is used to measure the vibration of the tool. Then, these surface roughness and the tool vibration values were recorded and inserted into the Design Of Expert ( DOE ) software to do the analysis. The combination values of cutting parameter with lowest surface value were selected. The best cutting parameters will be 2700rpm of spindle speed, 170mm/min of feed rate, 4.2mm depth of cut, 0.6mm width of cut and 20um cutting edge radius with 0.1964um surface roughness and 0.9058mm/s2 tool vibration. The optimized combination of parameters were obtained and do the validation. For the validation, the result of surface roughness and tool vibration from the Design of Expert software was compared with the surface roughness and tool vibration values from the CNC milling process. The percentage error for surface roughness is 7.32% and 1.44% percentage error for tool vibration. Both percentage error were small. Hence, the result can be consider as accurate.