Evaluation of Cutting-Edge Radius of a Cutting Tool for Milling of P20 Material to Achieve Optimal Surface Roughness.

Teoh, Yong Zhong (2020) Evaluation of Cutting-Edge Radius of a Cutting Tool for Milling of P20 Material to Achieve Optimal Surface Roughness. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

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. There is also some benefit that has led to this study, such as the machining industry, which is looking for better surface finishing for its finished product and better machining efficiency. Besides that, the surface roughness is one of the most commonly used criteria to determine the quality of milled steel and it is affected by various cutting parameter such as depth of cut, cutting speed and feed rate. Surface roughness is one of the important factors for making molds and dies such as P20 steel. Moreover, this project evaluation of cutting-edge radius for the milling process of P20 materials for better surface finish. Some standard tools and techniques are required for the analysis of cutting parameter to get the optimum results. A set of optimum cutting parameters and suitable design of tool geometry was contributing to better surface finish. It also contributes to improve abrasion resistance of materials and longer the tool life. In addition, the selection of cutting-edge radius, 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. The Surface roughness also depends the numerous attributes of parts, such as contact causing surface friction, wearing, light reflection, heat transmission, ability of distributing and holding a lubricant, coating, or resistance fatigue. Those are the factors should be considered into machining process. 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 surface performance which is surface roughness 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. The ‘Time 3220’ surface roughness tester was used for surface roughness measurement. The hand held Analyzer Type 2270 and Accelerometer Type 4507 were used for vibration recording purpose. The procedure and methods of experiment was discussed detailed at Methodology in Chapter 3. The optimal cutting-edge radius is 20μm 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 Chapter 4.