A Study on Effect of Spindle Speed on Tool Wear for Ball Nose End Mill on STAVAX Material

Phun, Kah Kitt (2023) A Study on Effect of Spindle Speed on Tool Wear for Ball Nose End Mill on STAVAX Material. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

One of the most often used technologies of precision manufacturing is high-speed milling using a coated carbide ball end mill. It is a fast machining operation that combines a very high spindle speed and feed rate with a little side step and a small down step. In this project, the experimental works were performed to examine that the tool wear is highly impacted by few parameters. There are three tools with gash rake angle of -3º, chisel distance of 33%(0.08mm) and central offset value of 1.5%(0.09mm) will be used to evaluate the tool wear during dry milling of ESR AISI 420 modified STAVAX stainless steel using a coated carbide cutting tool. The dimension of workpiece provided is 155mm in length, 84mm in width and 30mm in height. The tool dimensions are fixed diameter of 6mm, flute number of 2 and length of 50mm. On the other hands, the cutting parameter likes spindle speed is set in range of 9000, 10000 and 13000rpm. The other parameters like depth of cut is fixed at 0.06mm, width of cut is set at 0.07mm and feed rate is 2000mm/min. The response of experimental work, tool wear will be measured by using Dino Lite Basic AM4113ZT microscope. After the experiments were carried out, the crater wear was observed on rake face of the cutting tool and it was increased with an increase in spindle speed. The width of crater wear was increased when increasing the spindle speed from 9000rpm to 11000rpm while the width of crater wear was decreased but increased in depth when increasing the spindle speed from 9000rpm to 11000rpm. Not only that, the flank wear was observed on top of cutting tool with an flank wear width of 0.013mm, 0.025mm and 0.031mm when cutting at 9000rpm, 11000rpm and 13000rpm respectively.