Evaluation of Cutting-Edge Radius of a Cutting Tool for Milling of Die Aluminium Casting Material to Achieve Optimal Tool Wear

Song, Kah Soon (2020) Evaluation of Cutting-Edge Radius of a Cutting Tool for Milling of Die Aluminium Casting Material to Achieve Optimal Tool Wear. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

In the metal machining industry, sustainability plays a dominant role in fabricating well finished products to customer. Life expectancy of a tool is that important when comes to the products quality assurance and control. Hence, this specific project aids to reduce the tool wear by means of optimizing the cutting-edge radius were determined when machining Die Aluminium Casting material in wet cutting condition. DAC material which is a hardened materials mostly used in die-casting because it has a very high hardness with 52HRC. Due to its hardness the cutting tools were used in milling this type of materials will be worn out easily and the surface roughness will tends to be very coarse. The surface finish become very coarse and affect the product in a poor condition. The manufacture wish to be evaluated out a cutting tool that can be used in this range of materials and implement with the optimum cutting parameter. The following extensive literature review on key aspect relating to mill machining including the operational challenges, machine tools, tooling, cutting mechanisms were undertaken to evaluate the milling of hardened materials such as DAC materials with 52HRC. In this study, the objectives of this research such as to determine tool geometry of a milling tool for DAC milling through literature search has done which enable the tool manufacturing company to provide the specific tool geometry. Moreover, Design of Experiment (DOE) had been used to compute set of experiment parameters to run the research experiment. Moreover, a set of machining parameters including cutting feed, cutting speed, depth of cut, width of cut and cutting-edge radius (CER) for the machine the range of hardness as DAC material were generated by the DOE software. For this project, machining parameters such as the depth of cut, tool diameter, and cutting condition were constant whereas the cutting-edge radius (CER) and width of cut were varying. In this project tested on tool wear for a distance that had been set, so a few round of experiments were observed and measured. The Design of Experiment (DOE) was being utilized to design a set of experiments to test out the best set of machining parameters with lesser tool wear. To observe and analyse the tool wear conditions, the Dino-light microscope was chooser to do the observation. Therefore, there are total 9 runs of experiment that had been run in this research which each of the value of 10,20, and 30CER were run with the 0.1, 0.6 and 1.2mm width of cut that generated out from the DOE. By conducted the experiment the graph had been plotted. From the graph it can be seen that the trend of the 30CER was the optimum cutting tool compare with the rest. So, it can be concluded that the 30CER had the optimum tool wear in the various type width of cut. The results that had been also putted into the DOE software and generated the ANOVA table which shows that 30CER was the optimum one.