Evaluation of Cutting-Edge Radius for Milling of P20 Steel to Achieve Optimal Tool Wear

Chan, Yik Mun (2020) Evaluation of Cutting-Edge Radius for Milling of P20 Steel to Achieve Optimal Tool Wear. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

The demand for cost efficiency in production and the development of new products ranging widely in complexity, material composition, size, and surface finish have required industry to develop new cutting materials and to adopt new machining strategies for evaluation of cutting-edge radius. The design and development of cutting tool for milling requires a number of considerations such as thermal distribution, cutting force and torque applied to the tool, wear, vibration and more. This study is to design and develop a cutting tool for milling process. The cutting tool specifically end mill tool is designed by HPMT Industries Sdn Bhd and the experiment is carried out in IIUM with the CNC machine out there. Tool life span and its attainment criteria have played a highly significant role in controlling the quality of the product. Tool wear of cutting tool is actually one of the effects of the inappropriate combination of machining parameter applied during machining process. There are many methods to improve the tool life but this research focused on the evaluation combination of the parameter such as cutting-edge radius and width of cut. Evaluation of CER to get optimal tool wear on P20 material. It also contributes to improve abrasion resistance of materials and longer the tool life. This analysis and experiment would enable industries to overcome and recognize barriers to the machining of a variety of materials and thus improve their product quality in terms of tool life and surface finishing after machining. Lastly, the investigation of cutting-edge radius for 4-flute uncoated carbide end mill tool was studied in the project which in order to evaluation of cutting-edge radius of cutting tool in P20 milling to achieve optimal surface performance. In addition, the effect of the cutting-edge radius on tool performance which is tool wear and tool life in milling P20 material. In the research, the various of cutting-edge radius and width of cut were used to carry out the experiments. Experiments focusing on the effect of cutting-edge radius on surface finishing on P20 milling in different width of cut. Besides that, effect of cutting-edge radius on tool life could help to further explain the effect observed. In this experiment, dino-lite microscope play an very important role in order to get the high resolution of the image of the tool wear results. With the tool wear photo, result can be analyzed easily. The procedure and methods of experiment was discussed detailed at Methodology. The optimal cutting-edge radius is 30μm when cutting width equal to 0.1mm along the cutting tools. Besides that, the tool failure and tool chip were obtained at the experiment. The factors and solutions of tool failure and chipping were discussed further at the Result and Discussion. Last but not least, the selection of optimal cutting parameters and design of tool geometry are very important factor for each machining process which order to increase the quality of machined products and decreases the process time, to lower down the machining costs and to increase the production rate.