Effect of Cutting Feed Rate on Tool Wear for Ball Nose End Milling on STAVAX Material

Pua, Kai Xuen (2023) Effect of Cutting Feed Rate on Tool Wear 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

As the advance of the technology, the ways to manufacturing the hard workpiece such as stainless steel, titanium and aluminium are mostly done by Computer Numerical Control (CNC) machine nowadays. The convenience provided by the technologies has highly increased the efficiency of the production in shorter time. Milling is one of the manufacturing methods to produce the metal product which is also a common technique around the world. However, the cutting tools of the milling machines will face the problem of tool wear once the cutting tools run the cutting for a long period. The tool wear not only will shorten the service life of the tool but also down grade the surface finish quality of the workpiece. The proposal will investigate the effects cutting feed rate on tool wear for ball nose end milling on the workpiece. The machining parameter like feed rate and milling speed, and depth of cut are found that they can increase the tool wear in term of the increase of cutting force, vibration amplitude and the heat generated in the milling. The experiment of the proposal will be done by using TONGTAI CT-350 5 Axis CNC machine as the instrument with the employment of the BN45 Series ball end milling ball nose with diameter of 6mm and coated with tungsten carbide provided by sponsor company. STAVAX ESR will be chosen as the workpiece for the milling process. Lastly, the surface finishing quality is analysed by using the Olympus GX51 Microscope.