A Study on Surface Roughness and Tool Wear on Mild Steel Using Different Coated Carbide Tools

Liao, Kah Lerk (2018) A Study on Surface Roughness and Tool Wear on Mild Steel Using Different Coated Carbide Tools. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

In this research, the study for performance of cutting tools in milling process will be investigated. There are 3 types of cutting tools that will be investigate. The base material of cutting tools will be same, Cemented Tungsten Carbide, just the coating will be different. The first type is uncoated carbide End Mill, diameter 5mm. The second type is AlCrN coated carbide End Mill, diameter 5mm. The third type is AlTiN coated carbide End Mill, diameter 5mm. The work material that been used for this study is mild steel grade S275JR. A design of experiments (DOE) which is two level full factorial designs was used to conduct the experiments. There are 2 factors that will be considered in this research which are cutting speed (1591-3182 RPM) and feed rate (0.01-0.02mm/tooth). The investigation of the wear on the cutting tool will be conducted during and after the cutting process under the microscope, while the roughness of machined surface will be measured using a surface roughness tester. The results from this research show that result of surface roughness with coating cutter is better than uncoated. The optimum responses are with high cutting speed with low feed rate to get minimum value of the surface roughness. For experiment 1, optimum cutting parameter with cutting speed 3114 RPM, feed rate 0.01 mm/tooth, the desire surface roughness to get is 0.714946 μm. For experiment 2, optimum cutting parameter with cutting speed 3182 RPM, feed rate 0.01 mm/tooth, the desire surface roughness to get is 0.533775 μm. For experiment 3, optimum cutting parameter with cutting speed 3181 RPM, feed rate 0.01 mm/tooth, the desire surface roughness to get is 0.512359 μm. From this research, the result indicate that among three type of cutting tools, the best response, surface roughness can be obtain is using the AlTiN coating end mill.