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CHAPTER 1
INTRODUCTION
This chapter describes the introduction to the title of the project and briefly explains on the problem faced on the industry and also the planning of completing PSM 1 .This
chapter also includes the scope and important of carried this project.
1.1 Introduction
High speed machining was first develop by German inventor during year 1920 and now widely spread in variety of manufacturing industry included aerospace and automotive
sectors where to produce high precession and accuracy parts. Major advantages of high speed machining are high material removing rate, reduction of lead time and the most
important is increase parts precision and surface finish. Many industry nowdays facing challenge to improve the quality of products and processes with minimum cost and time
constraints.
Commonly, surface roughness is using to determine and evaluate the quality of product, so controlling the parameters in high speed milling are very important to produce a
perfect surface finish without damaging machine and cutting tools. Surface roughness also effect several functional attributes of parts such as contact causing surface friction,
wearing, light reflection, heat transmission or resisting fatigue. Therefore the desired finish surface is usually specified and the appropriate processes are selected to reach the
required quality. The dynamic and widespread of high speed machining operations in the coming decade have raised a need for seeking a systematic solution that can help to
2 solve the problem of surface roughness. It is advance to select the parameters of cutting
speed; spindle speed and depth of cut because these are the main factors that affect the surface roughness and also can be controllable.
The goal of the research is to determine the possible effect of high speed milling on the aluminum surface by conducting the surface roughness test of the workpieces that
produce. This included using the surface roughness tester to check for the surface roughness produce by different speed of cutting and the defects on the surface may lead
to major changes in the mechanical properties of the material such as reduction in fatigue life. The results from this research will assist to replace
the traditional ―trial and error‖ method by DOE method which may lead to the improvements in manufacturing
of aircraft and manufacturing industry. Aluminum 6061 is chosen as the material to test because it is widely used for construction of aircraft structures, such as wings and
fuselages, more commonly in automation precision parts.
1.2 Background of Problem
