Effects Of Workpiece And Tool Rigidity On Machining Performances.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
EFFECTS OF WORKPIECE AND TOOL RIGIDITY ON
MACHINING PERFORMANCES
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing process) (Hons.)
by
MOHD ZAID BIN AWANG
B 050910295
880217-11-5537
FACULTY OF MANUFACTURING ENGINEERING
2013
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: EFFECTS TO WORKPIECE AND TOOL RIGIDITY ON MACHINING
PERFORMANCES
________________
NAMA PENYELIA
Pensyarah,
SESI PENGAJIAN: 2012/13 Semester 2
Fakulti Kejuruteraan Pembuatan
Saya MOHD ZAID BIN AWANG
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN
1. TERHAD.
Laporan JIKA
PSM LAPORAN
adalah hakDIKELASKAN
milik Universiti
Teknikal
Malaysia
Melaka
SEBAGAI
TIDAK
TERHAD,
MAKAdan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
BORANG
INI TIDAK
PERLUsahaja
DISERTAKAN
LAPORAN PSM.
untuk tujuan
pengajian
dengan DALAM
izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysiasebagaimana yang termaktub
dalam AKTA RAHSIA RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tetap:
Cop Rasmi:
NO. 37, LORONG SENTOSA 2
KG TENGAH (F) NERAM SATU
24060 KEMAMAN, TERENGGANU
Tarikh: 3.JUNE. 2013
Tarikh: 3.JUNE. 2013
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai
SULIT atau TERHAD.
DECLARATION
I hereby declare that this report entitled “Effects of Workpiece and Tool Rigidity on
Machining Performances” is the result of my own research except as cited in the
references.
Signature
:
………………………………………….
Author’s Name
:
Mohd Zaid Bin Awang
Date
:
3 June 2013
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM
as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Process) (Hons.). The member of the supervisory is
as follow:
………………………………
(Official Stamp of Supervisor)
ABSTRAK
Keluli keras sering digunakan dalam industri acuan dan mati. Beberapa aplikasi yang
diperlukan untuk mempunyai cermin permukaan profil kualiti dan bentuk bentuk
bebas canggih serentak. Dalam amalan industri semasa, menggilap dan mencanai
sering dilakukan untuk mencapai yang diperlukan bahan kerja kekasaran permukaan
yang biasanya dilakukan secara manual oleh operator mahir. Jelas teknik-teknik yang
sedia ada untuk mencapai cermin kemasan permukaan untuk acuan dan mati
komponen mempunyai kecenderungan untuk produktiviti yang lebih rendah dan
kesukaran untuk memastikan ketepatan komponen. Di samping itu, persembahan
pemesinan dipengaruhi oleh banyak faktor seperti bahan kerja dan alat ketegaran,
memotong parameter, pemotong strategi jalan dan ciri-ciri yang ketara. Walau
bagaimanapun, dari semua faktor-faktor yang memberi kesan kepada prestasi
pemesinan, kesan bahan kerja dan ketegaran alat sering diabaikan. Oleh itu, kajian
ini akan mengkaji kesan bahan kerja dan ketegaran alat semasa proses pemesinan,
peredam getah berlaku pada bahan kerja dan alat memotong. Setiap teknik yang
dicadangkan akan menganalisis dan membandingkan untuk menilai prestasinya. Dua
jenis bahan yang digunakan untuk menyiasat kesan-kesan ketara ke atas ciri-ciri
pemesinan stabily dalam eksperimen aloi iaitu alumium 6000 dan AISI D2 keluli
alat.
i
ABSTRACT
Hardened steel is often used in mould and die industry. Some of the
application required to have mirror surface quality profile and sophisticated free form
shape simultaneously. In current industry practice, polishing and grinding is often
performed to achieve the required workpiece surface roughness which is generally
performed manually by a skilled operator. Distinctly the existing techniques on
achieving mirror surface finish for mould and die component have a tendency to
lower productivity and difficulty ind ensuring the component accuracy. In addition,
machining performances are affected by many factors such as workpiece and tool
rigidity , cutting parameter, cutter path strategy and material characteristic. However,
from all the factors that affect the machining performances, effects of workpiece and
tool rigidity are often neglected. Therefore , this study will investigate the effects of
workpiece and tool rigidity during the machining process, a rubber damper is place
on workpiece and the cutting tool. Each proposed technique will be analyse and
compare to evaluate its performance. Two types of material were used to investigate
the effects of material characteristics on machining stabily in the experiment namely
alumium alloys 6000 and AISI D2 tool steel.
ii
DEDICATION
This dedication is for my family, Mr. Dr Raja Izamshah and my teammate. Thanks to
them for always helping in the success of this study.
iii
ACKNOWLEDGEMENT
I would like to thanks to all peoples that involved in giving helps, guiding me in
order to learn new things and finish this final year project 2013. As we know,
Universiti Teknikal Malaysia Melaka (UTeM) has giving his entire student a task in
final year to carry out a research or project that relate with engineering and industrial
field. Here, I would like to thank all of the lecturer especially Dr. Raja Izamshah
Raja Abdullah as supervisor, staff and my friends that has helping me before and
during final year project who have teach and supporting me in doing this final year
project by teaching a lot of experiences, new things and at the same time always
guide me for better understanding in engineering sector especially Through this final
year project, I have been giving opportunity to carry out a research, machining
processing, experimental data, and using measurement equipment which all of this
things are really important to be learn in manufacturing industry. People say the best
way to learn new things is to experience it yourself. Lecturer and staff has give me
the first-hand experience of real research and project environment by taught me a lot
about the confronting real research issues where I can put in what I have been
studying into proper use.
iv
TABLE OF CONTENT
Abstrak
i
Abstract
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
viii
List of Figures
x
List Abbreviations, Symbols and Nomenclatures
xiii
CHAPTER 1: INTRODUCTION
1
1.1
Background
1
1.2
Problem statement
3
1.3
Objectives
3
1.4
Scope of the research
3
CHAPTER 2: LITERATURE REVIEW
4
2.1
CNC Milling 5 axis operation
4
2.1.1
4
Type of CNC Milling 5 Axis two general groups
2.2
Half Sphere Milling
5
2.3
Strategy in Half Sphere Milling – Zig zag
7
2.4
Consideration Material in Machining
8
2.4.1
Aluminium
8
2.4.2
Tool Steel
9
2.5
Machining Performance
11
2.5.1
Surface Roughness
11
2.5.2
Vibration Assisted machining
13
2.5.3
Tool wear
14
v
CHAPTER 3: METHADOLOGY
16
3.1
Introduction
16
3.2
Flow chart process
17
3.3
Process Planning
18
3.4
3.5
3.3.1
CATIA – Design Modelling
18
3.3.2
Create of half Sphere using CATIA Software
19
3.3.3
Detail Drawing and Dimension
20
Machining Process (CAM)
21
3.4.1
Drawing stock
21
3.4.2
Describes Milling Machine – CNC Milling 5 axis
22
3.4.3
Describes Axis
23
3.4.4
Describes cutting tool
23
3.4.5
Describes tool path
24
3.4.6
Determine generate NC code
25
3.4.7
Setup on CNC Milling Machine
26
3.4.8
Strategy Milling Technique
27
Performance Measurement
29
3.5.1
Surface roughness
30
3.5.2
Vibration amplitude machining
31
3.5.3
Tool wear
32
3.6
Machining Parameters
33
3.7
Analysis
34
3.8
Solution and Recommendation
34
vi
CHAPTER 4: RESULT AND ANALYSIS
35
4.1 Surface Roughness
36
4.1.1
Result
36
4.1.2
Discussion
39
4.2 Vibration Amplitude Machining
41
4.2.1
Result
42
4.2.2
Discussion
45
4.3 Tool wear
49
4.3.1
Result
49
4.3.2
Discussion
51
4.4 Statistical of Analysis data on Aluminium
53
4.4.1
Objective of Optimization
53
4.4.2
Validation
55
4.5 Statistical of Analysis data on Tool Steel
56
4.5.1
Objective of Optimization
57
4.5.2
Validation
58
CHAPTER 5: CONCLUSION AND FUTURE WORK
60
5.1 Conclusion
60
5.2 Future work
61
REFERENCES
62
APPENDICES
A
List of Respondents
B
Gantt chart
vii
LIST OF TABLES
2.1
This general characteristic of Aluminium alloy
2.2
Tool Steel of Mechanical properties
10
3.1
This is machining parameters in machining process
33
4.1
Average reading a surface roughness by Aluminium on normal
technique
4.2
36
Average reading a surface roughness by Tool Steel on normal
technique
4.3
36
Average reading a surface roughness by Aluminium on tool
damping technique
4.4
37
Average reading a surface roughness by Tool Steel on tool
damping technique
4.5
37
Average reading a surface roughness by Aluminium on
workpiece damping technique
4.6
38
Average reading a surface roughness by Tool Steel on workpiece
damping technique
4.7
38
Average reading a surface roughness by three technique on
Aluminium
4.8
39
Average reading a surface roughness by three technique on Tool
Steel
4.9
40
The result of average to vibration amplitude machining by
aluminium
4.10
45
The result of average to vibration amplitude machining by Tool
Steel
4.11
45
The average of measurement value to tool wear by Aluminium on
three technique
4.12
9
51
The average of measurement value to tool wear by Tool Steel on
three technique
52
viii
4.13
Design actual of response by Aluminium on the three technique
4.14
The result of response evaluation by using Design Expert on
53
Aluminium
55
4.15
Design actual of response by Tool Steel on the three technique
56
4.16
The result of response evaluation by using Design Expert on Tool
Steel
58
ix
LIST OF FIGURES
1.1
The half sphere modelling to produce 3 diamond mirror surface
2
profile
2.1
DMG DMU 50 Mono Block model of 5 Axis Milling operations
5
2.2
The expected of half sphere modelling on development
6
2.3
The CAD/CAM system used creates the 5 axis CNC part
programs, with the tool axis perpendicular to the surface
6
2.4
Selection of tool path is zig –zag way
7
2.5
Aluminium
8
2.6
Tool Steel
10
2.7
The schedule of evaluation measurement surface roughness
12
2.8
The Accelerometer system to detect of amplitude machining
13
performance.
2.9
Optical Microscopy structure on the tool wear
15
2.10
The type of tool failure mechanism
15
3.1
Flow chart of process planning
17
3.2
Modelling of half sphere design
19
3.3
Half sphere of dimension drawing on the actual modelling
20
3.4
Drawing stock
21
3.5
Describe of the CNC milling 5 Axis
22
3.6
Illustration motion of CNC milling 5 Axis Machine
22
3.7
Describe of define Axis reference
23
3.8
Define of tool selection using in machining programming
24
3.9
Describe of tool path way
24
3.10
Define of data input ,output and NC coding
25
x
3.11
Setup machining datum
26
3.12
Normal technique machining
27
3.13
Tool damping machining
28
3.14
Workpiece damping technique machining
29
3.15
Surface test device and testing measurement of surface roughness
30
3.16
The scrip resulting after surface roughness measuring
30
3.17
Accelerometer device and located a probe by area position
31
3.18
The plot of diagram showing evaluation measuring of vibration
amplitude
3.19
31
This is optical microscopy system to determine of tool wear
structure a condition
32
3.20
The specimen sample for evaluation of structure on tool wear
32
4.1
Actual Visual a modelling of half sphere after machining process
35
4.2
Actual Visual of Surface roughness by an Aluminum and Tool
Steel at normal technique
4.3
36
Actual visual of surface roughness by an Aluminum and Tool
Steel at Tool damping technique
4.4
37
Actual Visual of surface roughness by an Aluminum and Tool
Steel at workpiece damping technique
38
4.5
The graph of average surface roughness by Aluminum
39
4.6
The graph of average surface roughness by Tool Steel
40
4.7
The Vibration amplitude machining of measurement
performance system
4.8
41
The plot diagram of vibration amplitude machining by Aluminum
on normal technique
4.9
42
The plot diagram of vibration amplitude machining by Tool Steel
on normal technique
4.10
42
The plot diagram of vibration amplitude machining by Aluminum
on tool damping technique
43
xi
4.11
The plot diagram of vibration amplitude machining by Tool Steel
on tool damping technique
4.12
43
The plot diagram of vibration amplitude machining by
Aluminium on workpiece damping technique
4.13
The plot diagram of vibration amplitude machining by Tool Steel
on workpiece damping technique
4.14
44
44
The Graph of average vibration amplitude machining on
aluminium to the comparison by three technique machining
46
process
4.15
The Graph of average vibration amplitude machining on
aluminium to the comparison by three technique machining
process
47
4.16
Actual visual for tool wear by normal technique
49
4.17
Actual visual for tool wear by tool damping technique
50
4.18
Actual visual for tool wear by workpiece damping technique
50
4.19
The graph of average tool wear by aluminium
51
4.20
The graph of average tool wear by Tool Steel
52
4.21
The graph of one factor by surface roughness vs. Level technique
54
on aluminium
4.22
The graph of one factor by vibration amplitude machining vs.
54
Level technique on aluminium
4.23
The graph of one factor by tool wear vs. Level technique on
55
aluminium
4.24
The graph of one factor by surface roughness vs. Level technique
57
on Tool Steel
4.25
The graph of one factor by Vibration amplitude machining vs.
57
Level technique on Tool Steel
4.26
The graph of one factor by tool wear vs. Level technique on Tool
58
Steel
xii
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
Al
-
Aluminium
AISI D2
-
Tool Steel
ANOVA
-
Analysis of Variance
APT
-
Automatically programmed tool
C
-
Carbon
CATIA
-
Computer Aided Three dimensional interactive application
CAD
-
Computer Aided Design
CAM
-
Computer Aided Manufacturing
CNC
-
Computerized Numerical Control
Cr
-
Chromium
KHz
-
Kelvin hertz
Mm
-
millimetre
Min
-
minute
Mn
-
Mangan
Mo
-
Molybdenum
PCBN
-
Polycrystalline cubic boron nitride
P-1
-
Point 1
P-2
-
Point 2
P-3
-
Point 3
P-4
-
Point 4
P-5
-
Point 5
Rpm
-
Rotation per minute
Si
-
Silicon
NC
-
Numerical control
V
-
Vanadium
VAM
-
Vibration Assisted Machining
3D
-
Three dimension
µm
-
micro
xiii
CHAPTER 1
INTRODUCTION
This report described a project of “Effects of workpiece and tool rigidity on
machining performance”. This chapter explains the background, problem statement,
objective and scope of the project.
1.1
Background
In the manufacturing engineering sector is very challenging especially for produce a
product into the automotive factory. It’s very needed to higher quality according to a
specification standard on guideline of requirement. The stamping mould and dies are
used to produce high precision metal components which are identical in shape and
size. The mould and die fabrication normal accomplished by milling machining
operation where the operation assisted by CADCAM technology software to provide
design and machining automation. All general, there are three main necessary stages
of mould die machining, namely, a rough machining stage where the work piece
material is removed as quickly as possible, semi finishing machining stage where
machining is carried out to ensure consistent material removal rate and finish
machining stage where the emphasis is on work piece dimensional accuracy and
quality finish.
1
Figure 1.1: The half sphere modelling to produce 3 diamond mirror surface profile
The mould and die is further polished manually in order to get diamond finishing.
The multi-activities from rough to finish the product of mould and die based on
material requires a significant portion of the lead-time and substantially increased the
overall operational cost. Fine surface finish is essential not only to provide accurate
and stringent tolerance for complex stamping product but also provide optimum heat
transfer during quenching process. This multi-method process sequence consumed
numbers of cutting tools, facilities, highly skill manpower and long working hours to
achieve the desired product quality. In the research, to determine to optimum
condition the surface profile in mould dies to produce a smooth surface or smooth
integrity the mould die. Finally, the results from a research will provide useful
information to obtain fine optimum surface finish during machining mould and die
based material without further requirement of polishing activities. The information
obtained also will be useful as reference materials for machining in planning their
machining in requirement to produce maximize surface integrity, reduce process and
hence minimize operation costs in manufacture industries.
2
1.2
Problem Statement
Thus, this study, it’s will known that machining stability have a direct effect on
machining performance. Thus , critical on the machining stability need to be
understand. The will investigate effects of workpiece and tool rigidity on machining
performance and stability.
1.3
(a)
Objective
To investigate the effects of workpiece and tool rigidity on machining
performance( surface roughness, vibration amplitude and tool wear).
(b)
To evaluate the effects of workpiece material characteristic on machining
stability.
1.4
Scope of the research
In this research, a focus on assessing the ability to produce 3 diamond mirror surface
profile by using CNC Milling 5 Axis machining process. The three different
operations on machining techniques is normal technique, tool damping technique and
work piece damping technique .A Ball Mill to finishing cuts is used for half sphere
machining by Aluminium and Tool Steel (AISI D2) . The machining performance
includes surface roughness, cutting vibration machining and tool wear, were
measured of the result.
3
CHAPTER 2
LITERATURE REVIEW
This chapter explains a systematic method for identifying evaluating and interpreting
the work done by researchers, survey scholarly articles, journal, handbook and other
sources such as patent, journal and others. This chapter covering the literature review
of the topic specified.
2.1
CNC Milling 5 Axis Operation
In the most production to higher productive by using a CNC milling 5 axis
machining is designing as a highly sophisticated component that cannot operate by
CNC Milling 3 axis machining. The probability of performance very high accuracy
of the work when carry out of complex design. It is combined with the increasing
generate system software and offline CNC multi axis program has been in
regularized to 5 axis for improvement in productivity and output configurations.
2.1.1
Type of CNC Milling 5 Axis two general groups
The positioning of the work piece in several planes or a variety of angles to
the spindle, which then executes a 3-axis machining cycle. Five sections of a
prismatic part, plus any combination of compound angles can be machined in
one setup.
The continuous 5-axis cutting motion of sculptured surfaces, pockets or other
3-dimensional features, also in a single setup.
4
Figure 2.1: DMG DMU 50 Mono Block model of 5 Axis Milling operations
2.2
Half Sphere Milling
The modelling of half sphere is a complex shape to produce on the CNC 5 Axis
milling machine to operation . For the half sphere is complex surface are encountered
in many objects such as especially automobile industry component mould and die.
This is descriptive of half sphere a make to 3D of these surfaces is often produced by
combining together element such as among them cylinder, cones, sphere , Bezier and
spline surfaces using a Catia software system. This is geometric descried can then
especially be used to generate a tool path for controlling a CNC milling machine.
The actual machining of the complex surface on the design half sphere will be
broken down into three main methods.
5
In the roughing cuts, a large amount of material is removed to sphere the general
shape of a surface, as quickly as possible without bring the tool in contact with the
description surface. Next method, this is finishing cuts are used to remove the
remaining material. Typically a single point on a Ball Mill is used to generate the
desired surface profile. ( A. Warkentin, S. Bedi and F. Ismail, 1995)
Figure 2.2: The expected of half Sphere on development
Figure 2.3: The CAD/CAM system used creates the 5 axis CNC part programs, with the tool axis
perpendicular to the surface (R. Baptista, J.F Antune Simoes , 2000)
6
2.3
Tool Path Strategy in half sphere Milling – Zig-zag
The strategy to made half sphere is used of zig –zag tool path. This is zig- zag pattern
is cut first (Shown in heavy dotted lines). Then the outer tool path (light solid line) is
cut. Regardless of design of half sphere or number of islands, only one starter cut is
required at the beginning of the zig –zag. The cutting tool may or may not be
withdrawn and moved between completing the zig-zag and starting the outer tool
path. Based on the review research, the selection of tool path has the best method of
the machining operation. In the case of the zig-zag tool paths it is desired that the
tool moves in a straight line in the feed-forward direction. Planning tool motion on
the design surface guarantees straight line motion of the tool contact point, but the
tool center may not move in a straight line. On the other hand, tool path planning on
the offset surface ensures straight line motion of the tool center. Hence, in the current
approach, CL points have been directly planned on the offset surface generated
through the ITO. ( Debananda Misra, V. Sundararajan and Paul K. Wright, 2002)
Figure 2.4: Selection of Tool Path is Zig- zag way
7
EFFECTS OF WORKPIECE AND TOOL RIGIDITY ON
MACHINING PERFORMANCES
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing process) (Hons.)
by
MOHD ZAID BIN AWANG
B 050910295
880217-11-5537
FACULTY OF MANUFACTURING ENGINEERING
2013
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: EFFECTS TO WORKPIECE AND TOOL RIGIDITY ON MACHINING
PERFORMANCES
________________
NAMA PENYELIA
Pensyarah,
SESI PENGAJIAN: 2012/13 Semester 2
Fakulti Kejuruteraan Pembuatan
Saya MOHD ZAID BIN AWANG
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
NOTA: BORANG INI HANYA DIISI JIKA DIKLASIFIKASIKAN SEBAGAI SULIT DAN
1. TERHAD.
Laporan JIKA
PSM LAPORAN
adalah hakDIKELASKAN
milik Universiti
Teknikal
Malaysia
Melaka
SEBAGAI
TIDAK
TERHAD,
MAKAdan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
BORANG
INI TIDAK
PERLUsahaja
DISERTAKAN
LAPORAN PSM.
untuk tujuan
pengajian
dengan DALAM
izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysiasebagaimana yang termaktub
dalam AKTA RAHSIA RASMI 1972)
TERHAD
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tetap:
Cop Rasmi:
NO. 37, LORONG SENTOSA 2
KG TENGAH (F) NERAM SATU
24060 KEMAMAN, TERENGGANU
Tarikh: 3.JUNE. 2013
Tarikh: 3.JUNE. 2013
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai
SULIT atau TERHAD.
DECLARATION
I hereby declare that this report entitled “Effects of Workpiece and Tool Rigidity on
Machining Performances” is the result of my own research except as cited in the
references.
Signature
:
………………………………………….
Author’s Name
:
Mohd Zaid Bin Awang
Date
:
3 June 2013
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM
as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Process) (Hons.). The member of the supervisory is
as follow:
………………………………
(Official Stamp of Supervisor)
ABSTRAK
Keluli keras sering digunakan dalam industri acuan dan mati. Beberapa aplikasi yang
diperlukan untuk mempunyai cermin permukaan profil kualiti dan bentuk bentuk
bebas canggih serentak. Dalam amalan industri semasa, menggilap dan mencanai
sering dilakukan untuk mencapai yang diperlukan bahan kerja kekasaran permukaan
yang biasanya dilakukan secara manual oleh operator mahir. Jelas teknik-teknik yang
sedia ada untuk mencapai cermin kemasan permukaan untuk acuan dan mati
komponen mempunyai kecenderungan untuk produktiviti yang lebih rendah dan
kesukaran untuk memastikan ketepatan komponen. Di samping itu, persembahan
pemesinan dipengaruhi oleh banyak faktor seperti bahan kerja dan alat ketegaran,
memotong parameter, pemotong strategi jalan dan ciri-ciri yang ketara. Walau
bagaimanapun, dari semua faktor-faktor yang memberi kesan kepada prestasi
pemesinan, kesan bahan kerja dan ketegaran alat sering diabaikan. Oleh itu, kajian
ini akan mengkaji kesan bahan kerja dan ketegaran alat semasa proses pemesinan,
peredam getah berlaku pada bahan kerja dan alat memotong. Setiap teknik yang
dicadangkan akan menganalisis dan membandingkan untuk menilai prestasinya. Dua
jenis bahan yang digunakan untuk menyiasat kesan-kesan ketara ke atas ciri-ciri
pemesinan stabily dalam eksperimen aloi iaitu alumium 6000 dan AISI D2 keluli
alat.
i
ABSTRACT
Hardened steel is often used in mould and die industry. Some of the
application required to have mirror surface quality profile and sophisticated free form
shape simultaneously. In current industry practice, polishing and grinding is often
performed to achieve the required workpiece surface roughness which is generally
performed manually by a skilled operator. Distinctly the existing techniques on
achieving mirror surface finish for mould and die component have a tendency to
lower productivity and difficulty ind ensuring the component accuracy. In addition,
machining performances are affected by many factors such as workpiece and tool
rigidity , cutting parameter, cutter path strategy and material characteristic. However,
from all the factors that affect the machining performances, effects of workpiece and
tool rigidity are often neglected. Therefore , this study will investigate the effects of
workpiece and tool rigidity during the machining process, a rubber damper is place
on workpiece and the cutting tool. Each proposed technique will be analyse and
compare to evaluate its performance. Two types of material were used to investigate
the effects of material characteristics on machining stabily in the experiment namely
alumium alloys 6000 and AISI D2 tool steel.
ii
DEDICATION
This dedication is for my family, Mr. Dr Raja Izamshah and my teammate. Thanks to
them for always helping in the success of this study.
iii
ACKNOWLEDGEMENT
I would like to thanks to all peoples that involved in giving helps, guiding me in
order to learn new things and finish this final year project 2013. As we know,
Universiti Teknikal Malaysia Melaka (UTeM) has giving his entire student a task in
final year to carry out a research or project that relate with engineering and industrial
field. Here, I would like to thank all of the lecturer especially Dr. Raja Izamshah
Raja Abdullah as supervisor, staff and my friends that has helping me before and
during final year project who have teach and supporting me in doing this final year
project by teaching a lot of experiences, new things and at the same time always
guide me for better understanding in engineering sector especially Through this final
year project, I have been giving opportunity to carry out a research, machining
processing, experimental data, and using measurement equipment which all of this
things are really important to be learn in manufacturing industry. People say the best
way to learn new things is to experience it yourself. Lecturer and staff has give me
the first-hand experience of real research and project environment by taught me a lot
about the confronting real research issues where I can put in what I have been
studying into proper use.
iv
TABLE OF CONTENT
Abstrak
i
Abstract
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
viii
List of Figures
x
List Abbreviations, Symbols and Nomenclatures
xiii
CHAPTER 1: INTRODUCTION
1
1.1
Background
1
1.2
Problem statement
3
1.3
Objectives
3
1.4
Scope of the research
3
CHAPTER 2: LITERATURE REVIEW
4
2.1
CNC Milling 5 axis operation
4
2.1.1
4
Type of CNC Milling 5 Axis two general groups
2.2
Half Sphere Milling
5
2.3
Strategy in Half Sphere Milling – Zig zag
7
2.4
Consideration Material in Machining
8
2.4.1
Aluminium
8
2.4.2
Tool Steel
9
2.5
Machining Performance
11
2.5.1
Surface Roughness
11
2.5.2
Vibration Assisted machining
13
2.5.3
Tool wear
14
v
CHAPTER 3: METHADOLOGY
16
3.1
Introduction
16
3.2
Flow chart process
17
3.3
Process Planning
18
3.4
3.5
3.3.1
CATIA – Design Modelling
18
3.3.2
Create of half Sphere using CATIA Software
19
3.3.3
Detail Drawing and Dimension
20
Machining Process (CAM)
21
3.4.1
Drawing stock
21
3.4.2
Describes Milling Machine – CNC Milling 5 axis
22
3.4.3
Describes Axis
23
3.4.4
Describes cutting tool
23
3.4.5
Describes tool path
24
3.4.6
Determine generate NC code
25
3.4.7
Setup on CNC Milling Machine
26
3.4.8
Strategy Milling Technique
27
Performance Measurement
29
3.5.1
Surface roughness
30
3.5.2
Vibration amplitude machining
31
3.5.3
Tool wear
32
3.6
Machining Parameters
33
3.7
Analysis
34
3.8
Solution and Recommendation
34
vi
CHAPTER 4: RESULT AND ANALYSIS
35
4.1 Surface Roughness
36
4.1.1
Result
36
4.1.2
Discussion
39
4.2 Vibration Amplitude Machining
41
4.2.1
Result
42
4.2.2
Discussion
45
4.3 Tool wear
49
4.3.1
Result
49
4.3.2
Discussion
51
4.4 Statistical of Analysis data on Aluminium
53
4.4.1
Objective of Optimization
53
4.4.2
Validation
55
4.5 Statistical of Analysis data on Tool Steel
56
4.5.1
Objective of Optimization
57
4.5.2
Validation
58
CHAPTER 5: CONCLUSION AND FUTURE WORK
60
5.1 Conclusion
60
5.2 Future work
61
REFERENCES
62
APPENDICES
A
List of Respondents
B
Gantt chart
vii
LIST OF TABLES
2.1
This general characteristic of Aluminium alloy
2.2
Tool Steel of Mechanical properties
10
3.1
This is machining parameters in machining process
33
4.1
Average reading a surface roughness by Aluminium on normal
technique
4.2
36
Average reading a surface roughness by Tool Steel on normal
technique
4.3
36
Average reading a surface roughness by Aluminium on tool
damping technique
4.4
37
Average reading a surface roughness by Tool Steel on tool
damping technique
4.5
37
Average reading a surface roughness by Aluminium on
workpiece damping technique
4.6
38
Average reading a surface roughness by Tool Steel on workpiece
damping technique
4.7
38
Average reading a surface roughness by three technique on
Aluminium
4.8
39
Average reading a surface roughness by three technique on Tool
Steel
4.9
40
The result of average to vibration amplitude machining by
aluminium
4.10
45
The result of average to vibration amplitude machining by Tool
Steel
4.11
45
The average of measurement value to tool wear by Aluminium on
three technique
4.12
9
51
The average of measurement value to tool wear by Tool Steel on
three technique
52
viii
4.13
Design actual of response by Aluminium on the three technique
4.14
The result of response evaluation by using Design Expert on
53
Aluminium
55
4.15
Design actual of response by Tool Steel on the three technique
56
4.16
The result of response evaluation by using Design Expert on Tool
Steel
58
ix
LIST OF FIGURES
1.1
The half sphere modelling to produce 3 diamond mirror surface
2
profile
2.1
DMG DMU 50 Mono Block model of 5 Axis Milling operations
5
2.2
The expected of half sphere modelling on development
6
2.3
The CAD/CAM system used creates the 5 axis CNC part
programs, with the tool axis perpendicular to the surface
6
2.4
Selection of tool path is zig –zag way
7
2.5
Aluminium
8
2.6
Tool Steel
10
2.7
The schedule of evaluation measurement surface roughness
12
2.8
The Accelerometer system to detect of amplitude machining
13
performance.
2.9
Optical Microscopy structure on the tool wear
15
2.10
The type of tool failure mechanism
15
3.1
Flow chart of process planning
17
3.2
Modelling of half sphere design
19
3.3
Half sphere of dimension drawing on the actual modelling
20
3.4
Drawing stock
21
3.5
Describe of the CNC milling 5 Axis
22
3.6
Illustration motion of CNC milling 5 Axis Machine
22
3.7
Describe of define Axis reference
23
3.8
Define of tool selection using in machining programming
24
3.9
Describe of tool path way
24
3.10
Define of data input ,output and NC coding
25
x
3.11
Setup machining datum
26
3.12
Normal technique machining
27
3.13
Tool damping machining
28
3.14
Workpiece damping technique machining
29
3.15
Surface test device and testing measurement of surface roughness
30
3.16
The scrip resulting after surface roughness measuring
30
3.17
Accelerometer device and located a probe by area position
31
3.18
The plot of diagram showing evaluation measuring of vibration
amplitude
3.19
31
This is optical microscopy system to determine of tool wear
structure a condition
32
3.20
The specimen sample for evaluation of structure on tool wear
32
4.1
Actual Visual a modelling of half sphere after machining process
35
4.2
Actual Visual of Surface roughness by an Aluminum and Tool
Steel at normal technique
4.3
36
Actual visual of surface roughness by an Aluminum and Tool
Steel at Tool damping technique
4.4
37
Actual Visual of surface roughness by an Aluminum and Tool
Steel at workpiece damping technique
38
4.5
The graph of average surface roughness by Aluminum
39
4.6
The graph of average surface roughness by Tool Steel
40
4.7
The Vibration amplitude machining of measurement
performance system
4.8
41
The plot diagram of vibration amplitude machining by Aluminum
on normal technique
4.9
42
The plot diagram of vibration amplitude machining by Tool Steel
on normal technique
4.10
42
The plot diagram of vibration amplitude machining by Aluminum
on tool damping technique
43
xi
4.11
The plot diagram of vibration amplitude machining by Tool Steel
on tool damping technique
4.12
43
The plot diagram of vibration amplitude machining by
Aluminium on workpiece damping technique
4.13
The plot diagram of vibration amplitude machining by Tool Steel
on workpiece damping technique
4.14
44
44
The Graph of average vibration amplitude machining on
aluminium to the comparison by three technique machining
46
process
4.15
The Graph of average vibration amplitude machining on
aluminium to the comparison by three technique machining
process
47
4.16
Actual visual for tool wear by normal technique
49
4.17
Actual visual for tool wear by tool damping technique
50
4.18
Actual visual for tool wear by workpiece damping technique
50
4.19
The graph of average tool wear by aluminium
51
4.20
The graph of average tool wear by Tool Steel
52
4.21
The graph of one factor by surface roughness vs. Level technique
54
on aluminium
4.22
The graph of one factor by vibration amplitude machining vs.
54
Level technique on aluminium
4.23
The graph of one factor by tool wear vs. Level technique on
55
aluminium
4.24
The graph of one factor by surface roughness vs. Level technique
57
on Tool Steel
4.25
The graph of one factor by Vibration amplitude machining vs.
57
Level technique on Tool Steel
4.26
The graph of one factor by tool wear vs. Level technique on Tool
58
Steel
xii
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
Al
-
Aluminium
AISI D2
-
Tool Steel
ANOVA
-
Analysis of Variance
APT
-
Automatically programmed tool
C
-
Carbon
CATIA
-
Computer Aided Three dimensional interactive application
CAD
-
Computer Aided Design
CAM
-
Computer Aided Manufacturing
CNC
-
Computerized Numerical Control
Cr
-
Chromium
KHz
-
Kelvin hertz
Mm
-
millimetre
Min
-
minute
Mn
-
Mangan
Mo
-
Molybdenum
PCBN
-
Polycrystalline cubic boron nitride
P-1
-
Point 1
P-2
-
Point 2
P-3
-
Point 3
P-4
-
Point 4
P-5
-
Point 5
Rpm
-
Rotation per minute
Si
-
Silicon
NC
-
Numerical control
V
-
Vanadium
VAM
-
Vibration Assisted Machining
3D
-
Three dimension
µm
-
micro
xiii
CHAPTER 1
INTRODUCTION
This report described a project of “Effects of workpiece and tool rigidity on
machining performance”. This chapter explains the background, problem statement,
objective and scope of the project.
1.1
Background
In the manufacturing engineering sector is very challenging especially for produce a
product into the automotive factory. It’s very needed to higher quality according to a
specification standard on guideline of requirement. The stamping mould and dies are
used to produce high precision metal components which are identical in shape and
size. The mould and die fabrication normal accomplished by milling machining
operation where the operation assisted by CADCAM technology software to provide
design and machining automation. All general, there are three main necessary stages
of mould die machining, namely, a rough machining stage where the work piece
material is removed as quickly as possible, semi finishing machining stage where
machining is carried out to ensure consistent material removal rate and finish
machining stage where the emphasis is on work piece dimensional accuracy and
quality finish.
1
Figure 1.1: The half sphere modelling to produce 3 diamond mirror surface profile
The mould and die is further polished manually in order to get diamond finishing.
The multi-activities from rough to finish the product of mould and die based on
material requires a significant portion of the lead-time and substantially increased the
overall operational cost. Fine surface finish is essential not only to provide accurate
and stringent tolerance for complex stamping product but also provide optimum heat
transfer during quenching process. This multi-method process sequence consumed
numbers of cutting tools, facilities, highly skill manpower and long working hours to
achieve the desired product quality. In the research, to determine to optimum
condition the surface profile in mould dies to produce a smooth surface or smooth
integrity the mould die. Finally, the results from a research will provide useful
information to obtain fine optimum surface finish during machining mould and die
based material without further requirement of polishing activities. The information
obtained also will be useful as reference materials for machining in planning their
machining in requirement to produce maximize surface integrity, reduce process and
hence minimize operation costs in manufacture industries.
2
1.2
Problem Statement
Thus, this study, it’s will known that machining stability have a direct effect on
machining performance. Thus , critical on the machining stability need to be
understand. The will investigate effects of workpiece and tool rigidity on machining
performance and stability.
1.3
(a)
Objective
To investigate the effects of workpiece and tool rigidity on machining
performance( surface roughness, vibration amplitude and tool wear).
(b)
To evaluate the effects of workpiece material characteristic on machining
stability.
1.4
Scope of the research
In this research, a focus on assessing the ability to produce 3 diamond mirror surface
profile by using CNC Milling 5 Axis machining process. The three different
operations on machining techniques is normal technique, tool damping technique and
work piece damping technique .A Ball Mill to finishing cuts is used for half sphere
machining by Aluminium and Tool Steel (AISI D2) . The machining performance
includes surface roughness, cutting vibration machining and tool wear, were
measured of the result.
3
CHAPTER 2
LITERATURE REVIEW
This chapter explains a systematic method for identifying evaluating and interpreting
the work done by researchers, survey scholarly articles, journal, handbook and other
sources such as patent, journal and others. This chapter covering the literature review
of the topic specified.
2.1
CNC Milling 5 Axis Operation
In the most production to higher productive by using a CNC milling 5 axis
machining is designing as a highly sophisticated component that cannot operate by
CNC Milling 3 axis machining. The probability of performance very high accuracy
of the work when carry out of complex design. It is combined with the increasing
generate system software and offline CNC multi axis program has been in
regularized to 5 axis for improvement in productivity and output configurations.
2.1.1
Type of CNC Milling 5 Axis two general groups
The positioning of the work piece in several planes or a variety of angles to
the spindle, which then executes a 3-axis machining cycle. Five sections of a
prismatic part, plus any combination of compound angles can be machined in
one setup.
The continuous 5-axis cutting motion of sculptured surfaces, pockets or other
3-dimensional features, also in a single setup.
4
Figure 2.1: DMG DMU 50 Mono Block model of 5 Axis Milling operations
2.2
Half Sphere Milling
The modelling of half sphere is a complex shape to produce on the CNC 5 Axis
milling machine to operation . For the half sphere is complex surface are encountered
in many objects such as especially automobile industry component mould and die.
This is descriptive of half sphere a make to 3D of these surfaces is often produced by
combining together element such as among them cylinder, cones, sphere , Bezier and
spline surfaces using a Catia software system. This is geometric descried can then
especially be used to generate a tool path for controlling a CNC milling machine.
The actual machining of the complex surface on the design half sphere will be
broken down into three main methods.
5
In the roughing cuts, a large amount of material is removed to sphere the general
shape of a surface, as quickly as possible without bring the tool in contact with the
description surface. Next method, this is finishing cuts are used to remove the
remaining material. Typically a single point on a Ball Mill is used to generate the
desired surface profile. ( A. Warkentin, S. Bedi and F. Ismail, 1995)
Figure 2.2: The expected of half Sphere on development
Figure 2.3: The CAD/CAM system used creates the 5 axis CNC part programs, with the tool axis
perpendicular to the surface (R. Baptista, J.F Antune Simoes , 2000)
6
2.3
Tool Path Strategy in half sphere Milling – Zig-zag
The strategy to made half sphere is used of zig –zag tool path. This is zig- zag pattern
is cut first (Shown in heavy dotted lines). Then the outer tool path (light solid line) is
cut. Regardless of design of half sphere or number of islands, only one starter cut is
required at the beginning of the zig –zag. The cutting tool may or may not be
withdrawn and moved between completing the zig-zag and starting the outer tool
path. Based on the review research, the selection of tool path has the best method of
the machining operation. In the case of the zig-zag tool paths it is desired that the
tool moves in a straight line in the feed-forward direction. Planning tool motion on
the design surface guarantees straight line motion of the tool contact point, but the
tool center may not move in a straight line. On the other hand, tool path planning on
the offset surface ensures straight line motion of the tool center. Hence, in the current
approach, CL points have been directly planned on the offset surface generated
through the ITO. ( Debananda Misra, V. Sundararajan and Paul K. Wright, 2002)
Figure 2.4: Selection of Tool Path is Zig- zag way
7