Evaluation of Cutting-Edge Radius (CER) of a Cutting Tool for Milling of Die Aluminium Casting (DAC) Material to Achieve Optimal Surface Roughness

Yong, Boon Hann (2020) Evaluation of Cutting-Edge Radius (CER) of a Cutting Tool for Milling of Die Aluminium Casting (DAC) Material to Achieve Optimal Surface Roughness. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Die Aluminium Casting (DAC) material or hard material with 52 HRC are very difficult to machine by operator as its high hardness of material which cause the machined surface to be unsatisfied by the user and the short tool life of the cutting tool. Surface roughness is one the most important criteria to define the quality of a finished product. Not only that, there are different tool geometry for different application such as roughening and finishing which cause the stock level for tool manufacturing company to increase and hence the cost of operation increase. Therefore, tool manufacturing company is looking for a standardize tool geometry of cutting-edge radius (CER) which can suitable for each of the application and can achieve surface performance simultaneously. In this study, the objectives of this research such as to determine CER value of a milling tool for DAC cutting 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 and had used to data collection and analysis. Finally, objective of investigate the effect of CER value and width of cut in terms of surface performance had also been done which able to validate the optimal CER value and width of cut from ANOVA outputs. The machine parameter had set to be constant along the experiment such as spindle speed, feed rate and wet cutting condition which able to evaluate the CER value. The width of cut and CER value of cutting tool had been set to be manipulate along the experiment and paired with each other to identify the optimal value of CER and width of cut. Hence, there are 9 runs of experiment that had been run in this research which each of the value of CER paired with different width of cut that generated out from DOE. For the surface roughness had set to be the responding in this research as the surface roughness is the main concern in this research. The conclusion of this research is that tool geometry with 30 μm CER had achieved the optimal surface roughness for 0.1 mm width of cut, while tool geometry with 20 μm CER had achieved the optimal surface roughness for 1.2 mm width of cut and for 10 μm CER had achieved the optimal surface roughness for 0.6 mm width of cut. Vibration result that obtained from experiment is just to validate the result and the vibration trend is used for comparing the vibration between different of workpiece material. For validation result from ANOVA, tool wear is taken into consideration as the tool manufacturing is looking for cutting tool with specific value of CER of tool geometry that able to provide a better tool life and better surface finishing.