Effect of Tool Wear in STAVAX Machining with Ball Nose End Mills Under Variable Speed and Rake Angle

Tee, Zhong Zhe (2026) Effect of Tool Wear in STAVAX Machining with Ball Nose End Mills Under Variable Speed and Rake Angle. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This study investigates the effect of spindle speed and gash rake geometry on tool wear and wear progression of carbide coated ball nose end mills during the machining of STAVAX ESR under tilted dry cutting conditions over a cumulative cutting length of 480 m. The work focuses on abrasive wear as the dominant wear mechanism and flank wear as the principal wear mode, given their strong influence on tool life and surface quality. Experimental trials were carried out using two tools with gash rake angles of −10◦ and −1◦ at spindle speeds of 9000, 11000 and 13000 rpm, with feed rate, axial depth of cut and radial width of cut fixed at 3000 mm/min, 0.08 mm and 0.1 mm respectively to isolate the effects of speed and tool geometry. Maximum flank wear width