Tool Wear Study Negative Rake Angle Carbide Coated Ball Mill Machining STAVAX

Tan, Er-Vin (2026) Tool Wear Study Negative Rake Angle Carbide Coated Ball Mill Machining STAVAX. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This study investigated tool wear on a carbide-coated ball mill with a negative rake angle, used for high-precision machining of STAVAX steel. STAVAX is a hard, corrosion-resistant martensitic stainless steel used for applications like injection molds, but its properties make it challenging to machine, with tool wear being a critical issue. The goal of this research was to quantify and model the relationship between tool wear and machining distance to create a predictive framework for managing tool life. Machining experiments were conducted, and tool wear data was collected at set distance intervals. This data was analyzed using polynomial regression analysis up to the fifth degree to accurately represent the complex, non-linear progression of tool wear, which includes initial, steady-state, and accelerated wear phases. The experimental results showed a strong and predictable relationship between tool wear and machining distance. The polynomial regression models had a high coefficient of determination (fi2), confirming their reliability for predicting tool wear. This study successfully developed a quantitative tool for predicting the remaining useful life of a ball mill.The findings offer significant practical benefits for industry. The predictive models allow engineers to optimize machining strategies, reduce downtime and costs, and improve the overall efficiency and reliability of manufacturing processes involving STAVAX steel