A Study on Evaluating Machining Condition and Cutting Edge Radius to Improve Surface Roughness in Milling SUS316 Material

Bong, Joo Siong (2020) A Study on Evaluating Machining Condition and Cutting Edge Radius to Improve Surface Roughness in Milling SUS316 Material. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Surface roughness and tool vibration are very strong significant indicator of product quality. This is because surface roughness greatly affects the cost of production and the mechanical performance. Basically the results of surface roughness have significant effects on a few parameters such as cutting speed, feed rate, width of cut, depth of cut and cutting edge radius. Therefore, the way to reduce the surface roughness is to evaluate those parameters during the milling operation. In this study, we collaborated with HPMT Industries Sdn Bhd. and University Islam Antarabangsa Malaysia (UIAM) to complete this research. The workpiece that was used for this research was SUS 316 stainless steel. The size of the workpiece was 140mm x 110 x 50mm. The cutting tool was sponsored by HPMT Industries Sdn Bhd. The material of the tool was uncoated carbide end milling tool. The diameter of the tool was 6mm with 4-flutes. The cutting operation was conducted in University Islam Antarabangsa Malaysia (UIAM) because UIAM using the 3-axis CNC machine. The cutting operation was carried out under wet condition. The cutting speed was fixed at 4500RPM and the feed rate fixed at 350mm/min. Also, the depth of cut was set at 6mm. The widths of cut were varied between 0.1mm, 0.6mm and 1.2mm. The cutting edge radius was tested for 30μm, 40μm and 50μm. The responding variables from the experiment were surface roughness and tool vibration. Bruel & Kjaer 2250 vibration meter was used to measure the tool vibration. After completing the cutting operation, the TIME 3220 surface roughness tester was used to measure the surface roughness of the workpiece. The data was recorded and analysed using the the Design of Expert (DOE) software. Finally, an optimum combination of parameters was obtained. The lowest reading of surface roughness obtain from the experiment is 0.566μm by using 50μm CER with 0.1mm width of cut at 880mm distance. Meanwhile, the lowest reading of surface roughness obtain from the Design of Expert (DOE) is 1.132μm by using 50μm CER with 0.1mm width of cut. In fact, there had some small error occurred during the experiment which includes systematic errors and random errors. To prevent this kind of error, there is some way to solve the issue. For example, use the quality equipment, calibrate equipment properly, controlled environment and do the double-check all the time.