A Study on Comparison of Tool Wear and Chip Formation during Milling for 5083 Aluminium and S275JR Mild Steel

Lee, Eric Wei Chun (2018) A Study on Comparison of Tool Wear and Chip Formation during Milling for 5083 Aluminium and S275JR Mild Steel. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Milling materials using different types of cutting tools perform diversely. Thus, it is essential to study the effects of cutting during machining. 5083 Aluminium and S275JR Mild Steel are the widely-used materials in the industry. Hence, it is crucial to examine the surface roughness, tool wear and chip formation of the materials throughout the milling done by the CNC machine. The experiment will be conducted by Johnford VMC 850 CNC milling machine with the cutting tool of 5mm uncoated carbide single end three flutes cutting tool. Different value of cutting speed that selected in the experiments are 1581rpm and 3182rpm, while the feed rate ranges from 0.01 to 0.02 mm/tooth. Apart from that, the depth of cut is kept constant at 0.1mm. During the milling process, collection of the chip that formed will be carried out throughout the whole milling process and formation of chips will be observed and magnified by using Dimo Lite Basic AM2111device. Besides, microscopic observation on the tool wear will also be done by using a microscopic camera (Olympus GX51 Digital Inverted Metallurgical Microscope) and data will be collected to analyses the tool wear. Last but not least, after the experiment was done, the work piece will also need to be analyses by using surface roughness of the workpiece materials that will be conducted by TIME 3220 surface roughness device to get the optimum machining condition. From this project, it come out with conclusion that the optimum condition for three parameters, tool wear, chip formation and surface roughness is cutting speed set at high speed and feed rate set at low feed rate, as for this project the high speed is at 3182rpm and low feed rate is at 0.01mm/tooth. With this cutting speed and feed rate, lowest tool wear, shorter and thicker chips with higher shear layer thickness and low surface roughness will be formed and this will eventually increase efficiency and performance of machining, and also reduce cost of time needed in machining.