Effect Of Inclined Ball Milling Process On Aluminium Alloy.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
EFFECT OF INCLINED BALL MILLING PROCESS ON
ALUMINIUM ALLOY
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing
Engineering (Manufacturing Process) with Honours.
By
NUR HANANI BT MAT ZALI
FACULTY OF MANUFACTURING ENGINEERING
April 2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
BORANG PENGESAHAN STATUS TESIS*
JUDUL: EFFECT OF INCLINED BALL MILLING PROCESS ON ALUMINIUM ALLOY
SESI PENGAJIAN: 2009/2010
Saya
NUR HANANI BT MAT ZALI
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan ( ,r)
D
SULIT
D
TERHAD
EJ
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
Disah ffn oleh:
(TANDATANGAN PENULIS)
ｾ＠
Alamat Tetap:
335 JALAN MUSTAFFA,
KG PENAMBANG 15350,
KOTA BHARU,
KELANTAN
Tarikh:9 APRIL 2010
ｾ＠
t? ... ｾ＠
(TANDJ ｔａｾ＠
GAN PENYELIA)
MOHAMAD RIOZUAN BH·• J;
•
Pensyarah
Cop Rasm1:
Tarikh:
Fakulti Kejuruteraan f'embuatan
Universiti Teknikal Malayaia Melaka
2 ｾ＠ /
i
'r"IltD
* Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau
disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda
(PSM).
** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau
TERHAD.
DECLARATION
I hereby, declared this report entitled "Effect of Inclined Ball Milling Process on
Aluminium Alloys " is the results of my own research
except as cited in references.
ﾷ ﾷ ﾷ ｾﾷ
Signature
Author's Name
ﾷ ﾷ ﾷ ﾷ＠
NUR HANANI MAT ZALI
19th APRIL, 201 0
Date
11
APPROVAL
This PSM submitted to the senate ofUTeM and has been as partial fulfillment of the
requirements for the degree of Bachelor of Manufacturing Engineering
(Manufacturing Process). The member of the supervisory committee is as follow:
MOHA
n
rah
Fakulti Kejurute an Pembuatan
.••••.• !J.'liyPr,iP.ｔＡｾｴｫａｉＮｦｙｩｬ＠
ｾｬ＠
....
Mr. Mohamad Ridzuan bin Jamli
Main Supervisor
lll
ABSTRACT
Milling is one of the fundamental forms of machining operation among several
industrial machining processes. The inclination of the cutting tool is one of the
important factors that influence the surface finish which become a requirements in a
variety of manufacturing industries including the aerospace, die-mold and
automotive industries where complex surfaces and geometries are machined. The
three sectors are stressed most on the quality of the surface finish. Thus, the main
objective for this study is to investigate the effect of the inclined ball end milling to
the scallop height of the Aluminium Alloys surface. Machining parameters involved
in this study are lead angle, tilt angle and step over. The material used to test its
scallop is Aluminium Alloys. Full factorial design of DOE by using the Design
Expert software was applied in order to determine the test run for the experiment. It
also used to analyze the data obtained from the experiments. There were two method
used in this study in order to get the accurate result which are Simulation modeling
using CATIA software and Experimental machining using the 3-axis CNC milling
machine. The result for both processes showed that the scallop height was decreased
when the tilt angle increased.
lV
ABSTRAK
Proses kisar adalah salah satu bentuk: asas operasi pemesinan antara proses
pemesinan yang terdapat dalam industri. Kecondongan mata alat merupakan salah
satu factor penting yang mempengaruhi permukaan akhir produk yang menjadi
keperluan dalam pelbagai industri pembuatan termasuklah sector ruang angkasa,' diemold'dan automotif. Ketiga-tiga sektor ini sangat menekankan terhadap kualiti
permukaan yang terhasil. Oleh itu, objektif utama kajian ini adalah untuk: mengkaji
kesan peningkatan sudut mata alat dalam 'ball end milling' terhadap kekasaran
permukaan bahan kerja. Pembolehubah yang terlibat dalam kajian ini adalah sudut
'lead', sudut 'tilt' dan 'step over'. Bahan yang akan digunakan untuk: menguji
kekasaran permukaannya adalah aloi Aluminium.
Kaedah "full factorial"
menggunakan 'Design Expert' digunakan untuk: menentukan bilangan ujikaji perlu di
jalankan. Ia juga akan digunakan kemudian bagi menganalisis data yang akan
diperolehi. Dua jenis ujikaji telah dilakukan untuk: mendapat hasil yang lebih tepat
telah digunakan iaitu Model simulasi dari 'CATIA' dan experiment mesin
menggunakan 3 paksi mesin CNC. Pencapaian yang didapati melalui kedua-dua uji
kaji tersebut menunjukkan ketinggian lekukkan di permukaan adalah berkuarang
apabila sudut 'tilt' bertambah.
v
DEDICATION
To my beloved parents Mat Zali bin Junoh and Azizah Ismail, thank you for your
continuous support and thanks for everything. My sisters and brothers, thank you for
encouraging me to do well in this writing.
VI
ACKNOWLEDGEMENTS
All praise to almighty Allah S.W.T. I am thankful for the strength and patience He
has given within me to complete this Bachelor Degree Project as a part of program
Manufacturing Engineering. I am Deepings grateful and thankful to my supervisor,
Mr. Mohamad Ridzuan bin Jamli that had been so helpful in supervised, taught and
relayed the technique and knowledge when undergo my thesis. I am realize that his
guidance and advice has made this a much better thesis. I also wish my appreciation
to Mr. Khairul Efendy Mansor, the technician who had lending his hand in helping
me through the machine handling. I am particularly indebted for your help and
experience through my thesis. A special word of thanks also is due to the people
closer to me such as friends and colleagues who gave me opportunity to develop my
writing and to all the UTeM lecturers and staffs. More, I like to take this opportunity
to say at this juncture, it is only logical for me to pay tribute to my family. Their
undivided love and support are the beacons that have continued to motivate me
through the harshest of situations and I believe it will also spur me on to greater
achievement in the future. And with the blessing of Allah I could finish this thesis.
Thanks to all of you. Finally, I would like to wish thank you a lot to anybody who
has given all the support and contribution to me in this thesis directly or indirectly.
Thanks to all of you.
Vll
TABLE OF CONTENT
Declaration
11
Aproval
111
Abstract
IV
Abstrak
v
Dedication
vi
Acknowledgements
Vll
Table of contents
Vlll
List of figures
XI
List of tables
xiii
List of abbreviation
XIV
1. CHAPTER 1: INTRODUCTION
1
1.1
I
Background of the Study
1.1.1 Ball End Milling
2
1.1.2 The Effect of the Inclined Ball Milling Process
2
1.2
Problem Statement
4
1.3
Objective
5
1.4
Scope of Project
5
1.5
Structure of Project
6
1.6
Gantt Chart
8
2. CHAPTER 2: LITERATURE REVIEW
10
2.1
Introduction
10
2.2
Tool Orientations
10
2.3
Lead and Tilt angle
12
2.3.1
Lead angle
12
2.3.2 Tilt angle
2.4
Effect of Lead and Tilt Together with Step Over
Vlll
13
14
2.5
Effect on Cutting Speed and Depth of cut
16
2.6
DepthofCut
18
2.7
Cutter Path Orientation.
20
2.7.1
Four Types of Cutter Path Orientation.
20
2.8
Feed (mm/tooth)
22
2.9
Work piece material
23
2.9.1 Aluminium alloys
23
2.10
24
Cutting Tool material
2.10.1 High-speed Steel
24
2.10.2 Cast-Cobalt Alloys
25
2.10.3 Carbide
25
2.11
24
Cutting Fluids
2.11.1 Lubricant
27
2.12
27
Surface quality
2.12.1 Surface Finish Parameters
28
3. CHAPTER 3: METHODOLOGY
30
3.1
Introduction
30
3.2
Identification of Process Parameters
32
3.2.1
Simulation Machining Parameter
33
3.2.2 Experimental Parameter
3.2.3 Design Expert Software analysis
33
34
3.3
Simulation Process (CATIA)
36
3.4
Machining Process
38
3.4.1
Machining Tool
39
3.5
Measurement
40
ix
4. CHAPTER 4: RESULT AND DISCUSSION
42
4.1
Result
42
4.1.1
Results for the Simulation Modeling Process
42
4.1.2
Analysis ofVariance (ANOVA)
43
4.1.3
Diagnostic
44
4.1.4 Model Graph
47
4.2
Experimental and Machining Process
51
4.2.1
Analysis OfVariance (ANOVA)
52
4.2.2
Diagnostic
53
4.2.3
Model Graph
55
4.3
Comparison between Simulation Process and Experimental machining
process
60
4.4
Machining error
61
4.4.1
Vibration
61
4.4.2
Tool wear
61
4.4.3
Parallax error
62
S. CHAPTERS: CONCLUSION AND RECOMMENDATION
63
5.1
Conclusion
63
5.2
Recommendation
64
REFERRENCES
65
APENDICES
A
Drafting sheet for Experimental Machining work piece
B
Drafting sheet for Simulation Modeling work piece
C
Result sheet for Simulation Modeling
D
Analysis of optimization for Simulation Modeling Process
E
Analysis of optimization for Experimental Machining
F
Stereo Zoom Microscope Specification
X
LIST OF FIGURES
1.1
Definition of tool orientation and inclination.(Terai et. al.)
1.2
An illustration and tool chip contact areas of four different paths
3
Orientations. (C.K. Toh)
4
1.3
The Process Flow Chart of the PSM I and PSM II
7
2.1
Coordinates system of5-axis milling operations (Ozturk et al.,2009)
11
2.2
Lead and Tilt angle. (Ozturk et al.,2009)
12
2.3
Indentation case (Ozturk et al.,2009)
13
2.4
Scallop height,h5, a) s ｾ＠ 2Ro cost b) s 2:: 2Ro cost (Ozturk et al.,2009)
15
2.5
Tool inclination 45°
17
2.6
Tool inclination 38°
17
2.7
An illustration of four different cutter path orientation.( Toh.2004)
20
2.8
Tool chip contact areas on cutter plane based on different cutter
pathorientation.
( Toh,2004)
20
2.9
Cutting Forces Measured With Different Cutter Orientation.
2.10
The path-interval scallop and feed interval scallop of ball end milling.
21
(J.S. Chen,2005)
22
2.11
HSS end milling cutter
24
2.12
Carbide ball end milling cutters
25
3.1
Flowchart of Methodology for the process
31
3.2
Simulation modelling process
36
3.3
Measurement of the scallop height using CATIA software
37
3.4
Projection View of the work piece
38
3.5
Surface Machined
39
3.6
Haas CNC 3-axis milling machine
39
3.7
Carbide Cutting Tool
40
3.8
Stereo Zoom Microscope EMZ-13 TR
41
3.9
Scallop height measurement
41
4.1
Normal plot of residuals
44
4.2
Graph of Residual vs predicted
45
4.3
Graph of residuals vs. run
45
XI
4.4
Box-Cox Plot for Power transforms
46
4.5
Interaction between Tilt angle and Lead angle
47
4.6
Interaction between Step over and Lead angle
48
4.7
Interaction between Tilt angle and step over
49
4.8
Interaction between lead angle and step over
50
4.9
Normal plot of residuals
53
4.10
Residual vs. Predicted
54
4.11
Residuals vs. Run
54
4.12
Box-Cox for Power transforms
55
4.13
Interaction of Lead Angle and Tilt angle
56
4.14
Interaction of Step Over and Lead angle
57
4.15
Interaction of Lead angle and Step Over
58
4.16
Interaction of Tilt Angle and Step Over
59
Xll
LIST OF TABLES
1.6
Ghantchart
8
2.1
Milling Machine Cutting Speed
16
2.2
Comparison between Cutting Speed and Depth of cut due to the Angle
18
2.3
Typical properties of Aluminium Alloys
23
3.1
Parameter for simulation machining process
33
3.2
Experimental Parameter
33
3.3
Design Summary for Simulation Modelling Process
35
3.4
Design Summary for Experimental machining
35
4.1
Results for ANOVA
43
4.2
Result for the Machining Experiment
51
4.3
ANOVA for the experimental machining
52
Xlll
LIST OF ABBREVIATION
AA
Arithmetic Average
ANOVA
Analysis OfVariance
CATIA
Computer Aided Three-dimensional Interactive
Application
NC
Numerical Control
CLA
Centre Line Average
CNC
Computer Numerical Control
XlV
CHAPTER 1
INTRODUCTION
1.1 Background of the Study
Manufacturing of parts with complex surfaces brings additional challenges such as
tool accessibility and contouring. Five- axis milling provides much better
accessibility with the help of increased tool orientation capability. However, 5-axis
milling also brings extra difficulties due to the complicated process geometry and
mechanics. Lead and tilt angles determine orientation of cutting tool and the
engagement region, and affect the mechanics and dynamics of the process. Local
chip thickness, cutting force coefficients, dynamic forces and stability are affected
by lead and tilt angles. Improper tool orientation may result in decreased
productivity and part quality due to higher cutting forces, surface form errors and
process instability. Thus, lead and tilt angles are very important parameters in 5-axis
milling processes. Effects of lead and tilt angles on the process are not known very
well, and cannot be easily estimated unlike parameters such as feed rate and cutting
depths. Lead and tilt angles have effects on different factors such as tool tip contact
with the work piece, scallop height, cutting forces, torque, form errors and stability.
(Ozturk et al.,2009)
1
1.1.1
Ball End Milling
A ball end mill is well suited to milling many types of materials, from plastics to
steel alloys and titanium. The toughness and durability of the cutting edge is very
high in ball end mills because of the rounded edge design. This fact is actually just a
by product of the rounded cutting edge. Originally it was rounded for a specialized
purpose, namely for milling grooves with a semi-circular cross-section. This type of
groove is an important part of the metal bearings used in many machines.
Another benefit of the way the ball end mill is designed is that it can handle very
high feed rates, meaning it can mill the material very quickly. This gives it great
productivity for use in today’s milling machines. The smooth geometry of the cutting
tip also translates into lower cutting forces, giving the cutter added strength under
pressure. Since it is less likely to break under normal forces, the ball end mill is also
highly cost-effective for the applications to which it is suited.
Ball end mills are almost always made of tungsten carbide, a high-strength metallic
compound containing tungsten and carbon. Tungsten carbide powder is pressed into
rods, which are then ground and sharpened to various specifications. A typical ball
end mill will often be manufactured with a protective coating. These coatings usually
contain titanium mixed with other elements such as carbon and aluminium.
1.1.2
The Effect of the Inclined Ball Milling Process
As already it has been researched, various cutting process conditions are very
important in the developed surface roughness of machined surface. One such cutting
condition with important effect in the quality of surface is the inclination angle
between the cutting tool and the work piece, during the cutting process. The
placement of cutting tool can be differentiated, depending on the inclination angle
2
between the tool and the processed surface and the feed direction. These result in
different milling strategies that consequently lead to different surface quality. The
reasons for this behaviour are the different cutting speed of the cutting edge, the
different shapes of chips per case and the variability of the developed cutting forces.
Figure 1.1: Definition of tool orientation and inclination.(Terai et. al.)
Fig.1 illustrates the definition of the tool orientation. Z axis is the normal direction of
the surface of the work piece in machining. Y axis is the direction of feeding the
tool. So, x-axis is the direction of pick feed. On this coordination 2 defined for the
tool orientation. One is the angle between z axis and a plane including the tool
rotation axis and y axis. It is called “the angle of pick feed direction ω p”. In this case
we define another coordination xtytzt. This coordination is inclined ωp around y axis.
So yt zt plane include the tool rotation axis. In this plane the angle between the tool
rotation axis and z t axis is called “the feed direction angle ωf”. (Terai et. al.)
3
Figure 1.2: An illustration and tool chip contact areas of four different path orientations. (C.K. Toh)
1.2
Problem Statement
The finish milling on the plane surface using ball end milling generally
results in poor tool life since the effective cutting speed at its tip is zero and the
effective cutting speed is very small. The different contact area of the cutting tool
will lead to the different cutting speed of the machining process. Step over also will
influence the scallop height produce on the surface. The different of inclination angle
and cutter path orientation will result the different surface finish. This experimental
study is purposely to investigate the inclination angle as well as the cutter path
orientation in order to get the best surface.
4
1.3
Objective
The purposes of this study are:
i.
Investigation using the CATIA simulation
ii.
To investigate the effect of the inclined ball end milling to the scallop height
of the Aluminium Alloys surface.
iii.
To compare the results between the experimental machining with the CATIA
simulation machining
1.4
Scope of Project
This study is mainly about the experimental test of the Ball end milling process to
study the effects of the inclination of Ball End Milling process on the Aluminium
Alloys. The study will include the effect of the inclination to the surface roughness
of the Aluminium Alloys using four different cutter path orientation of the cutting
tool. Different inclination angle of the Ball end milling machine will result different
surface roughness. Hence, this study is to discover the suitable inclination angle to
produce the best surface roughness of Aluminium Alloys. The study takes into
account the orientation of the cutting tool, with respect to the work piece, offering
the possibility to alter the tool inclination angles. The study is focus primarily on the
Ball End Milling Process on Aluminium Alloys to identify the effect of the
inclination angle of the process on the Aluminium Alloys. The study is considered in
three aspects which are inclination angle of the cutting tool (30°), speed of the
cutting tool, and also the cutter path orientation consist of horizontal upward,
horizontal downward, vertical upward, vertical downward. The method use in the
study are calculation, modelling of the process using CATIA, basic machining of 5axis Milling Machine, and measurement for the surface roughness which using
surface profilometers. Above all, this study uses the Design of Experiment (D.O.E)
method in analyzing the result.
5
1.5
Structure of Project
Generally, this report is divided into two parts which are Projek Sarjana Muda
(PSM) I and PSM II. In total, this report contains of five main chapters. These
chapters are separated into two parts which the first part contains three chapters
which are introduction, literature review and methodology whereas the second part
conducts the two more chapters, results and discussion and finally, conclusion and
recommendation of this study.
In the first chapter, Introduction, briefly explain the background of the study about
the Effects of Inclined Ball end Millings process and introduction on the ball end
milling generally. It also contains of the problem statement, objectives, scope and
structure of this project. All theories were taken and referred to the articles, journals,
and some books related to the study are explain in detail in Chapter 2, Literature
Review.
In chapter 3, Methodology, all methods that have been use are explained specifically
in term to achieve the objectives and obtain the result of the study. On the other
hand, in Chapter 4, for the results and discussion, this report are focus primarily on
the data that been collected and identify the influence factor that achieve the result.
Besides, suggestion for improvement on the Ball end Milling process also been
given in this chapter.
In the last chapter, Chapter 5, Conclusion and Recommendation which conclude this
study and also included some suggestion in order to improve this study for future.
Finally, all the chapters are compiled separately in sequences in order to give a clear
view to the readers. The flow chart below shows the general flow of the Projek
Sarjana Muda (PSM) that will be held in two semesters.
6
Start
Projek sarjana muda (PSM) I
Choose the project title and
do research
Do the simulation modelling
using CATIA software.
NO
NO
Suitable?
Do the experimental test
using 3-axis CNC machine on
the workpiece.
YES
Conform the project title with
the supervisor.
Collect the data of the
experiment and see the
results.
Start research on the Inclined
Ball End Milling and gather
all the data.
NO
Objectives
achieved?
Do the modelling using
CATIA and see the result.
YES
Conclude the project.
Start working on the
calculation of the angle.
PSM presentation
Projek sarjana muda (PSM) II
End
Figure 1.3: The Process Flow Chart of the PSM I and PSM II
7
1.6 Gantt Chart
Table 1.1: Gantt chart for PSM1
1
Yeat
Activity
PSM title confirmation
2
Problem statement identification
3
objective and scope of study
4
Finding literature review
5
PSM 1 report writing
6
PSM 1 report review
7
PSM 1 report submission
8
Preparation for PSM 1 presentation
9
PSM 1 presentation
No
July
Aug
Planning
Actual
8
2009
Sept
Oct
Nov
Table 1.2: Gantt Chart for PSM II
1
Year
Activity
Improvement on PSM 1
2
Finding literature review
3
Simulatio Modelling using CATIA
4
Machining and material preparation
5
Machining process
6
Surface roughness measurement
7
Data Analysis using Design Expert
8
PSM 2 report writing
9
PSM 2 review
10
PSM 2 submission
11
Preparation for PSM 2 presentation
12
PSM 1 presentation
No
Jan
Feb
9
2009
Mar
Apr
May
EFFECT OF INCLINED BALL MILLING PROCESS ON
ALUMINIUM ALLOY
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing
Engineering (Manufacturing Process) with Honours.
By
NUR HANANI BT MAT ZALI
FACULTY OF MANUFACTURING ENGINEERING
April 2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
BORANG PENGESAHAN STATUS TESIS*
JUDUL: EFFECT OF INCLINED BALL MILLING PROCESS ON ALUMINIUM ALLOY
SESI PENGAJIAN: 2009/2010
Saya
NUR HANANI BT MAT ZALI
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan ( ,r)
D
SULIT
D
TERHAD
EJ
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
Disah ffn oleh:
(TANDATANGAN PENULIS)
ｾ＠
Alamat Tetap:
335 JALAN MUSTAFFA,
KG PENAMBANG 15350,
KOTA BHARU,
KELANTAN
Tarikh:9 APRIL 2010
ｾ＠
t? ... ｾ＠
(TANDJ ｔａｾ＠
GAN PENYELIA)
MOHAMAD RIOZUAN BH·• J;
•
Pensyarah
Cop Rasm1:
Tarikh:
Fakulti Kejuruteraan f'embuatan
Universiti Teknikal Malayaia Melaka
2 ｾ＠ /
i
'r"IltD
* Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau
disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda
(PSM).
** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau
TERHAD.
DECLARATION
I hereby, declared this report entitled "Effect of Inclined Ball Milling Process on
Aluminium Alloys " is the results of my own research
except as cited in references.
ﾷ ﾷ ﾷ ｾﾷ
Signature
Author's Name
ﾷ ﾷ ﾷ ﾷ＠
NUR HANANI MAT ZALI
19th APRIL, 201 0
Date
11
APPROVAL
This PSM submitted to the senate ofUTeM and has been as partial fulfillment of the
requirements for the degree of Bachelor of Manufacturing Engineering
(Manufacturing Process). The member of the supervisory committee is as follow:
MOHA
n
rah
Fakulti Kejurute an Pembuatan
.••••.• !J.'liyPr,iP.ｔＡｾｴｫａｉＮｦｙｩｬ＠
ｾｬ＠
....
Mr. Mohamad Ridzuan bin Jamli
Main Supervisor
lll
ABSTRACT
Milling is one of the fundamental forms of machining operation among several
industrial machining processes. The inclination of the cutting tool is one of the
important factors that influence the surface finish which become a requirements in a
variety of manufacturing industries including the aerospace, die-mold and
automotive industries where complex surfaces and geometries are machined. The
three sectors are stressed most on the quality of the surface finish. Thus, the main
objective for this study is to investigate the effect of the inclined ball end milling to
the scallop height of the Aluminium Alloys surface. Machining parameters involved
in this study are lead angle, tilt angle and step over. The material used to test its
scallop is Aluminium Alloys. Full factorial design of DOE by using the Design
Expert software was applied in order to determine the test run for the experiment. It
also used to analyze the data obtained from the experiments. There were two method
used in this study in order to get the accurate result which are Simulation modeling
using CATIA software and Experimental machining using the 3-axis CNC milling
machine. The result for both processes showed that the scallop height was decreased
when the tilt angle increased.
lV
ABSTRAK
Proses kisar adalah salah satu bentuk: asas operasi pemesinan antara proses
pemesinan yang terdapat dalam industri. Kecondongan mata alat merupakan salah
satu factor penting yang mempengaruhi permukaan akhir produk yang menjadi
keperluan dalam pelbagai industri pembuatan termasuklah sector ruang angkasa,' diemold'dan automotif. Ketiga-tiga sektor ini sangat menekankan terhadap kualiti
permukaan yang terhasil. Oleh itu, objektif utama kajian ini adalah untuk: mengkaji
kesan peningkatan sudut mata alat dalam 'ball end milling' terhadap kekasaran
permukaan bahan kerja. Pembolehubah yang terlibat dalam kajian ini adalah sudut
'lead', sudut 'tilt' dan 'step over'. Bahan yang akan digunakan untuk: menguji
kekasaran permukaannya adalah aloi Aluminium.
Kaedah "full factorial"
menggunakan 'Design Expert' digunakan untuk: menentukan bilangan ujikaji perlu di
jalankan. Ia juga akan digunakan kemudian bagi menganalisis data yang akan
diperolehi. Dua jenis ujikaji telah dilakukan untuk: mendapat hasil yang lebih tepat
telah digunakan iaitu Model simulasi dari 'CATIA' dan experiment mesin
menggunakan 3 paksi mesin CNC. Pencapaian yang didapati melalui kedua-dua uji
kaji tersebut menunjukkan ketinggian lekukkan di permukaan adalah berkuarang
apabila sudut 'tilt' bertambah.
v
DEDICATION
To my beloved parents Mat Zali bin Junoh and Azizah Ismail, thank you for your
continuous support and thanks for everything. My sisters and brothers, thank you for
encouraging me to do well in this writing.
VI
ACKNOWLEDGEMENTS
All praise to almighty Allah S.W.T. I am thankful for the strength and patience He
has given within me to complete this Bachelor Degree Project as a part of program
Manufacturing Engineering. I am Deepings grateful and thankful to my supervisor,
Mr. Mohamad Ridzuan bin Jamli that had been so helpful in supervised, taught and
relayed the technique and knowledge when undergo my thesis. I am realize that his
guidance and advice has made this a much better thesis. I also wish my appreciation
to Mr. Khairul Efendy Mansor, the technician who had lending his hand in helping
me through the machine handling. I am particularly indebted for your help and
experience through my thesis. A special word of thanks also is due to the people
closer to me such as friends and colleagues who gave me opportunity to develop my
writing and to all the UTeM lecturers and staffs. More, I like to take this opportunity
to say at this juncture, it is only logical for me to pay tribute to my family. Their
undivided love and support are the beacons that have continued to motivate me
through the harshest of situations and I believe it will also spur me on to greater
achievement in the future. And with the blessing of Allah I could finish this thesis.
Thanks to all of you. Finally, I would like to wish thank you a lot to anybody who
has given all the support and contribution to me in this thesis directly or indirectly.
Thanks to all of you.
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TABLE OF CONTENT
Declaration
11
Aproval
111
Abstract
IV
Abstrak
v
Dedication
vi
Acknowledgements
Vll
Table of contents
Vlll
List of figures
XI
List of tables
xiii
List of abbreviation
XIV
1. CHAPTER 1: INTRODUCTION
1
1.1
I
Background of the Study
1.1.1 Ball End Milling
2
1.1.2 The Effect of the Inclined Ball Milling Process
2
1.2
Problem Statement
4
1.3
Objective
5
1.4
Scope of Project
5
1.5
Structure of Project
6
1.6
Gantt Chart
8
2. CHAPTER 2: LITERATURE REVIEW
10
2.1
Introduction
10
2.2
Tool Orientations
10
2.3
Lead and Tilt angle
12
2.3.1
Lead angle
12
2.3.2 Tilt angle
2.4
Effect of Lead and Tilt Together with Step Over
Vlll
13
14
2.5
Effect on Cutting Speed and Depth of cut
16
2.6
DepthofCut
18
2.7
Cutter Path Orientation.
20
2.7.1
Four Types of Cutter Path Orientation.
20
2.8
Feed (mm/tooth)
22
2.9
Work piece material
23
2.9.1 Aluminium alloys
23
2.10
24
Cutting Tool material
2.10.1 High-speed Steel
24
2.10.2 Cast-Cobalt Alloys
25
2.10.3 Carbide
25
2.11
24
Cutting Fluids
2.11.1 Lubricant
27
2.12
27
Surface quality
2.12.1 Surface Finish Parameters
28
3. CHAPTER 3: METHODOLOGY
30
3.1
Introduction
30
3.2
Identification of Process Parameters
32
3.2.1
Simulation Machining Parameter
33
3.2.2 Experimental Parameter
3.2.3 Design Expert Software analysis
33
34
3.3
Simulation Process (CATIA)
36
3.4
Machining Process
38
3.4.1
Machining Tool
39
3.5
Measurement
40
ix
4. CHAPTER 4: RESULT AND DISCUSSION
42
4.1
Result
42
4.1.1
Results for the Simulation Modeling Process
42
4.1.2
Analysis ofVariance (ANOVA)
43
4.1.3
Diagnostic
44
4.1.4 Model Graph
47
4.2
Experimental and Machining Process
51
4.2.1
Analysis OfVariance (ANOVA)
52
4.2.2
Diagnostic
53
4.2.3
Model Graph
55
4.3
Comparison between Simulation Process and Experimental machining
process
60
4.4
Machining error
61
4.4.1
Vibration
61
4.4.2
Tool wear
61
4.4.3
Parallax error
62
S. CHAPTERS: CONCLUSION AND RECOMMENDATION
63
5.1
Conclusion
63
5.2
Recommendation
64
REFERRENCES
65
APENDICES
A
Drafting sheet for Experimental Machining work piece
B
Drafting sheet for Simulation Modeling work piece
C
Result sheet for Simulation Modeling
D
Analysis of optimization for Simulation Modeling Process
E
Analysis of optimization for Experimental Machining
F
Stereo Zoom Microscope Specification
X
LIST OF FIGURES
1.1
Definition of tool orientation and inclination.(Terai et. al.)
1.2
An illustration and tool chip contact areas of four different paths
3
Orientations. (C.K. Toh)
4
1.3
The Process Flow Chart of the PSM I and PSM II
7
2.1
Coordinates system of5-axis milling operations (Ozturk et al.,2009)
11
2.2
Lead and Tilt angle. (Ozturk et al.,2009)
12
2.3
Indentation case (Ozturk et al.,2009)
13
2.4
Scallop height,h5, a) s ｾ＠ 2Ro cost b) s 2:: 2Ro cost (Ozturk et al.,2009)
15
2.5
Tool inclination 45°
17
2.6
Tool inclination 38°
17
2.7
An illustration of four different cutter path orientation.( Toh.2004)
20
2.8
Tool chip contact areas on cutter plane based on different cutter
pathorientation.
( Toh,2004)
20
2.9
Cutting Forces Measured With Different Cutter Orientation.
2.10
The path-interval scallop and feed interval scallop of ball end milling.
21
(J.S. Chen,2005)
22
2.11
HSS end milling cutter
24
2.12
Carbide ball end milling cutters
25
3.1
Flowchart of Methodology for the process
31
3.2
Simulation modelling process
36
3.3
Measurement of the scallop height using CATIA software
37
3.4
Projection View of the work piece
38
3.5
Surface Machined
39
3.6
Haas CNC 3-axis milling machine
39
3.7
Carbide Cutting Tool
40
3.8
Stereo Zoom Microscope EMZ-13 TR
41
3.9
Scallop height measurement
41
4.1
Normal plot of residuals
44
4.2
Graph of Residual vs predicted
45
4.3
Graph of residuals vs. run
45
XI
4.4
Box-Cox Plot for Power transforms
46
4.5
Interaction between Tilt angle and Lead angle
47
4.6
Interaction between Step over and Lead angle
48
4.7
Interaction between Tilt angle and step over
49
4.8
Interaction between lead angle and step over
50
4.9
Normal plot of residuals
53
4.10
Residual vs. Predicted
54
4.11
Residuals vs. Run
54
4.12
Box-Cox for Power transforms
55
4.13
Interaction of Lead Angle and Tilt angle
56
4.14
Interaction of Step Over and Lead angle
57
4.15
Interaction of Lead angle and Step Over
58
4.16
Interaction of Tilt Angle and Step Over
59
Xll
LIST OF TABLES
1.6
Ghantchart
8
2.1
Milling Machine Cutting Speed
16
2.2
Comparison between Cutting Speed and Depth of cut due to the Angle
18
2.3
Typical properties of Aluminium Alloys
23
3.1
Parameter for simulation machining process
33
3.2
Experimental Parameter
33
3.3
Design Summary for Simulation Modelling Process
35
3.4
Design Summary for Experimental machining
35
4.1
Results for ANOVA
43
4.2
Result for the Machining Experiment
51
4.3
ANOVA for the experimental machining
52
Xlll
LIST OF ABBREVIATION
AA
Arithmetic Average
ANOVA
Analysis OfVariance
CATIA
Computer Aided Three-dimensional Interactive
Application
NC
Numerical Control
CLA
Centre Line Average
CNC
Computer Numerical Control
XlV
CHAPTER 1
INTRODUCTION
1.1 Background of the Study
Manufacturing of parts with complex surfaces brings additional challenges such as
tool accessibility and contouring. Five- axis milling provides much better
accessibility with the help of increased tool orientation capability. However, 5-axis
milling also brings extra difficulties due to the complicated process geometry and
mechanics. Lead and tilt angles determine orientation of cutting tool and the
engagement region, and affect the mechanics and dynamics of the process. Local
chip thickness, cutting force coefficients, dynamic forces and stability are affected
by lead and tilt angles. Improper tool orientation may result in decreased
productivity and part quality due to higher cutting forces, surface form errors and
process instability. Thus, lead and tilt angles are very important parameters in 5-axis
milling processes. Effects of lead and tilt angles on the process are not known very
well, and cannot be easily estimated unlike parameters such as feed rate and cutting
depths. Lead and tilt angles have effects on different factors such as tool tip contact
with the work piece, scallop height, cutting forces, torque, form errors and stability.
(Ozturk et al.,2009)
1
1.1.1
Ball End Milling
A ball end mill is well suited to milling many types of materials, from plastics to
steel alloys and titanium. The toughness and durability of the cutting edge is very
high in ball end mills because of the rounded edge design. This fact is actually just a
by product of the rounded cutting edge. Originally it was rounded for a specialized
purpose, namely for milling grooves with a semi-circular cross-section. This type of
groove is an important part of the metal bearings used in many machines.
Another benefit of the way the ball end mill is designed is that it can handle very
high feed rates, meaning it can mill the material very quickly. This gives it great
productivity for use in today’s milling machines. The smooth geometry of the cutting
tip also translates into lower cutting forces, giving the cutter added strength under
pressure. Since it is less likely to break under normal forces, the ball end mill is also
highly cost-effective for the applications to which it is suited.
Ball end mills are almost always made of tungsten carbide, a high-strength metallic
compound containing tungsten and carbon. Tungsten carbide powder is pressed into
rods, which are then ground and sharpened to various specifications. A typical ball
end mill will often be manufactured with a protective coating. These coatings usually
contain titanium mixed with other elements such as carbon and aluminium.
1.1.2
The Effect of the Inclined Ball Milling Process
As already it has been researched, various cutting process conditions are very
important in the developed surface roughness of machined surface. One such cutting
condition with important effect in the quality of surface is the inclination angle
between the cutting tool and the work piece, during the cutting process. The
placement of cutting tool can be differentiated, depending on the inclination angle
2
between the tool and the processed surface and the feed direction. These result in
different milling strategies that consequently lead to different surface quality. The
reasons for this behaviour are the different cutting speed of the cutting edge, the
different shapes of chips per case and the variability of the developed cutting forces.
Figure 1.1: Definition of tool orientation and inclination.(Terai et. al.)
Fig.1 illustrates the definition of the tool orientation. Z axis is the normal direction of
the surface of the work piece in machining. Y axis is the direction of feeding the
tool. So, x-axis is the direction of pick feed. On this coordination 2 defined for the
tool orientation. One is the angle between z axis and a plane including the tool
rotation axis and y axis. It is called “the angle of pick feed direction ω p”. In this case
we define another coordination xtytzt. This coordination is inclined ωp around y axis.
So yt zt plane include the tool rotation axis. In this plane the angle between the tool
rotation axis and z t axis is called “the feed direction angle ωf”. (Terai et. al.)
3
Figure 1.2: An illustration and tool chip contact areas of four different path orientations. (C.K. Toh)
1.2
Problem Statement
The finish milling on the plane surface using ball end milling generally
results in poor tool life since the effective cutting speed at its tip is zero and the
effective cutting speed is very small. The different contact area of the cutting tool
will lead to the different cutting speed of the machining process. Step over also will
influence the scallop height produce on the surface. The different of inclination angle
and cutter path orientation will result the different surface finish. This experimental
study is purposely to investigate the inclination angle as well as the cutter path
orientation in order to get the best surface.
4
1.3
Objective
The purposes of this study are:
i.
Investigation using the CATIA simulation
ii.
To investigate the effect of the inclined ball end milling to the scallop height
of the Aluminium Alloys surface.
iii.
To compare the results between the experimental machining with the CATIA
simulation machining
1.4
Scope of Project
This study is mainly about the experimental test of the Ball end milling process to
study the effects of the inclination of Ball End Milling process on the Aluminium
Alloys. The study will include the effect of the inclination to the surface roughness
of the Aluminium Alloys using four different cutter path orientation of the cutting
tool. Different inclination angle of the Ball end milling machine will result different
surface roughness. Hence, this study is to discover the suitable inclination angle to
produce the best surface roughness of Aluminium Alloys. The study takes into
account the orientation of the cutting tool, with respect to the work piece, offering
the possibility to alter the tool inclination angles. The study is focus primarily on the
Ball End Milling Process on Aluminium Alloys to identify the effect of the
inclination angle of the process on the Aluminium Alloys. The study is considered in
three aspects which are inclination angle of the cutting tool (30°), speed of the
cutting tool, and also the cutter path orientation consist of horizontal upward,
horizontal downward, vertical upward, vertical downward. The method use in the
study are calculation, modelling of the process using CATIA, basic machining of 5axis Milling Machine, and measurement for the surface roughness which using
surface profilometers. Above all, this study uses the Design of Experiment (D.O.E)
method in analyzing the result.
5
1.5
Structure of Project
Generally, this report is divided into two parts which are Projek Sarjana Muda
(PSM) I and PSM II. In total, this report contains of five main chapters. These
chapters are separated into two parts which the first part contains three chapters
which are introduction, literature review and methodology whereas the second part
conducts the two more chapters, results and discussion and finally, conclusion and
recommendation of this study.
In the first chapter, Introduction, briefly explain the background of the study about
the Effects of Inclined Ball end Millings process and introduction on the ball end
milling generally. It also contains of the problem statement, objectives, scope and
structure of this project. All theories were taken and referred to the articles, journals,
and some books related to the study are explain in detail in Chapter 2, Literature
Review.
In chapter 3, Methodology, all methods that have been use are explained specifically
in term to achieve the objectives and obtain the result of the study. On the other
hand, in Chapter 4, for the results and discussion, this report are focus primarily on
the data that been collected and identify the influence factor that achieve the result.
Besides, suggestion for improvement on the Ball end Milling process also been
given in this chapter.
In the last chapter, Chapter 5, Conclusion and Recommendation which conclude this
study and also included some suggestion in order to improve this study for future.
Finally, all the chapters are compiled separately in sequences in order to give a clear
view to the readers. The flow chart below shows the general flow of the Projek
Sarjana Muda (PSM) that will be held in two semesters.
6
Start
Projek sarjana muda (PSM) I
Choose the project title and
do research
Do the simulation modelling
using CATIA software.
NO
NO
Suitable?
Do the experimental test
using 3-axis CNC machine on
the workpiece.
YES
Conform the project title with
the supervisor.
Collect the data of the
experiment and see the
results.
Start research on the Inclined
Ball End Milling and gather
all the data.
NO
Objectives
achieved?
Do the modelling using
CATIA and see the result.
YES
Conclude the project.
Start working on the
calculation of the angle.
PSM presentation
Projek sarjana muda (PSM) II
End
Figure 1.3: The Process Flow Chart of the PSM I and PSM II
7
1.6 Gantt Chart
Table 1.1: Gantt chart for PSM1
1
Yeat
Activity
PSM title confirmation
2
Problem statement identification
3
objective and scope of study
4
Finding literature review
5
PSM 1 report writing
6
PSM 1 report review
7
PSM 1 report submission
8
Preparation for PSM 1 presentation
9
PSM 1 presentation
No
July
Aug
Planning
Actual
8
2009
Sept
Oct
Nov
Table 1.2: Gantt Chart for PSM II
1
Year
Activity
Improvement on PSM 1
2
Finding literature review
3
Simulatio Modelling using CATIA
4
Machining and material preparation
5
Machining process
6
Surface roughness measurement
7
Data Analysis using Design Expert
8
PSM 2 report writing
9
PSM 2 review
10
PSM 2 submission
11
Preparation for PSM 2 presentation
12
PSM 1 presentation
No
Jan
Feb
9
2009
Mar
Apr
May