3.6.1.1 Surface
Roughness Measurement
41 3.6.2
The Metallurgy
Microscope 42
3.6.3 Dial
Caliper 43 3.7 Analyze the Data 44
4.0 RESULTSANALYISIS
45 4.1
Introduction 45
4.2 Surface
Roughness Result
45 4.2.1 Analysis for Significant Parameter
47 4.2.2 Surface Roughness Analysis for Mild Steel Material
47 4.2.3 Surface Roughness Analysis for Tool Steel Material
51 4.3
Chip Thickness
Result 56 4.3.1 Chip Thickness Analysis for Mild Steel
57 4.3.2 Chip Thickness Analysis for Tool Steel
58 4.4
Observation of
Tool Wear
60
5.0 DISCUSSIONS
64 5.1
Tool Length
64 5.2
Speed and
Feed Rate
Factor 65
5.3 Tool
Wear 66
6.0 CONCLUSION AND RECOMMENDATIONS
67 6.1
Conclusion 67
6.2 Recommendation
68
REFERENCES 69
APPENDIX A
71
vii
LIST OF FIGURES
2.1 Effect milling cutting diameter workpiece travel
7 2.2
Tool path direction in three-axis ball-end milling of an inclined surface 8
2.2a Up-
ramping 8
2.2b Down
ramping 8 2.2c
Down-cutting contouring
8 2.2d
Up-cutting countering
8 2.3
Type of
milling cutter
11 2.4
Deflection test on the machine and result for ball-end mill Ø 8mm. 11
2.5 Deflection verification test of the cantilever beam model, and points
where the
deflection is
measured 12
2.6 Diagram representing the tests performed on the machine
13 2.7
Slot C and Hole B cutting test along X axis in forward direction. 14
2.8 Representative scanning electron microscopy SEM figures of tool wear 17
2.9 Chip
Form Produced
in Machining
Operation 19 2.10
Profile of the machined surface and workpiece simulation deflected during
unstable milling 22
2.11 Pair means comparison for spindle levels
23 2.12
Pair means comparison for depth levels 23
3.1 Methodology
Flow Chart
28 3.2
Workpiece 34
3.3 HAAS
CNC Milling
machine 35
3.4 Jig
use 38
3.5 Set
the programme
code 39
3.6 Tool
length Measurement
39 3.7
Machine operation
to the
workpiece 39
3.8 Finish
machining 39
3.9 End
mill cutting
tool 40
viii
3.10 Portable
Surface Roughness
Tester 41
3.11 Surface
roughness measurement
42 3.12
Metallurgy Microscope 42
3.13 Dial
Calliper 43
3.14 Measure
the chip
thickness 44
4.1 Estimated effects and coefficients for Ra
47 4.2
Normal probability plot of the standardized
effects 48
4.3 Pareto
chart of
the standardized
effects 54
4.4 Main effects plot data means for Ra
49 4.5
Interaction plot data means for Ra 50
4.6 Estimated effects and coefficients for Ra
52 4.7
Normal probability plot of the standardized
effects 52
4.8 Pareto
chart of
the standardized
effects 53
4.9 Main effects plot data means for Ra
54 4.10
Interaction plot data means for Ra 55
4.11 Estimated effects and coefficients for chip thickness
57 4.12
Normal probability plot of the standardized
effects 58
4.13 Estimated effects and coefficients for Chip Thickness
59 4.14
Graph normal probability plot of the standardized effect 59
4.15 Observation
before milling
operation 61
ix
LIST OF TABLES
2.1 Classical
Array 26 2.2
Taguchi Arrays 26
3.1 Gantt
Chat for
PSM 1
29 3.2
Gantt Chat
for PSM
2 30
3.3 The Level of Process Parameter for Mild Steel
31 3.4
The Level of Process Parameter for Tool Steel 32
3.5 Orthogonal Array table for experiment use Mild Steel workpiece
32 3.6
Orthogonal Array table for experiment use Tool Steel workpiece 33
3.7 Machine Specification of CNC Milling Machine
36 3.8
The machining
G-Code programme
37
4.1 The
result for
Mild Steel
material 46
4.2 The
result for
Tool Steel
material 46
4.3 Mean value of surface roughness
for Mild Steel 1020
for each
2- way
interaction 51
4.4 Mean value of surface roughness
for Tool Steel
for each
2- way
interaction 55
4.5 Chip thickness result for Mild Steel
56 4.6
Chip thickness result for Tool Steel 57
4.7 Tool
wear of
cutting tool
60 4.8
Tool wear micro picture for Mild Steel material at 1218 tool length 61
4.9 Tool wear micro picture for Mild Steel material at 1418 tool length
62 4.10
Tool wear micro picture for Tool Steel material at 1218 tool length 62
4.11 Tool wear micro picture for Tool Steel material at 1418 tool length
63
x
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED NOMENCLATURE
- percent
µ -
micro µm
- micro meter
cm -
centimeter CAM
- computer aided manufacturing
CNC -
computer numerical control DOE
- design of experiment
DoF -
degree of freedom in
- inch
L
F -
distance to the force application point m
- meter
mm -
millimeter OA
- orthogonal Array
PC - personal
computer R
a
- arithmetic mean value
R
q
- root mean square average
R
t
- peak to peak surface rughness
RPM -
rotation per
minute
xi
CHAPTER 1
INTRODUCTION
1.0 Introduction
