A Study on Effect of Depth of Cut on Surface Roughness for Ball Nose End Milling on STAVAX Material

Toh, Heng Kit (2023) A Study on Effect of Depth of Cut on Surface Roughness for Ball Nose End Milling on STAVAX Material. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

A strong and important indication of product quality is surface roughness. This is due to the fact that surface roughness has a significant impact on manufacturing costs and mechanical performance. A few parameters, including cutting speed, feed rate, width of cut, and depth of cut are highly impacted by the surface roughness results. Therefore, evaluating such parameters throughout the milling process is the best method for reducing surface roughness. This study used the Stavax ESR workpiece. The cutting tool and the material of the tool was coated carbide ball nose end mill. The tool with 2-flutes and the cutting operationwas carried out under dry conditions. The cutting tools of end face designs have gash rake angle, k-value and γp-value. The experiments are carried out using three different cutting tool and the same tool end face design, with variations in the depth of cut of 0.04mm, 0.06mm, and 0.08mm. The cutting parameter such as cutting speed, width of cut and feed rate are fixed at 13000rpm, 0.1mm and 2500mm/min throughout the experiment. After completing three runs of the experiment, the surface roughness values for different depths of cut were obtained. The experiment was run using a 5-axis machining centre. The 3 sets of cutting tools with same gash rake angle, k-value and γp-value corresponding to the different depths of cut. The result of surface roughness was measured using contact type Mitutoyo surface roughness tester and the surface roughness pattern was observe using Leica microscope. The results obtained showed that the average surface roughness value increased as the depth of cut increased. The average surface roughness values of 1.994μm, 2.043μm, and 2.283μm for depths of cut of 0.04mm, 0.06mm, and 0.08mm, respectively. The result were analyzed and discussed in detail in the discussion section, which also included a thorough analysis of the surface roughness pattern.