A study on Optimum Cutting Condition to reduce Surface Roughness in Milling Aluminium using Carbide tool

Lee, Jin Khoon (2018) A study on Optimum Cutting Condition to reduce Surface Roughness in Milling Aluminium using Carbide tool. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

A machining product must go through several machining process before it able to hand over to the customer. A common problem found on the machining product will be the surface roughness. Surface roughness is actually determines how an object interacts with its environment. A bad surface roughness will affect the quality of the product, and increase the production cost and production time. Surface roughness is mainly cause by the cutting speed of the cutting tool, feed rate and also the depth of cut. Different cutting speed, feed rate and depth of cut will result in different surface roughness. Hence, optimize the parameter, which is cutting speed, feed rate and depth of cut will be the best to reduce the surface roughness on the machining products. In this project, 8 sets of parameters were constructed using Design Expert 6. 5mm diameter 3 flutes uncoated carbide was used to carry out the experiment. Alumnium work piece was chosen to be the machining product that for us to measure the surface roughness. Milling operation was carried out using the CNC milling machine, with the 8 sets of parameters that set as cutting speed, feed rate and depth of cut in the CNC milling machine. After the experiment was carried out, the surface roughness for each of the parameters on each of the aluminium work piece was measured using the TIME3220 surface roughness tester. All surface roughness value was import into the design expert 6 and analyzed using 2-level factorial. Then, an optimum surface roughness value was obtained.