Background of the Project

1 CHAPTER 1 INTRODUCTION

1.1 Background of the Project

Machining can be defined as a chip formation process in fabricating engineering part. Machining process is a typical way to remove a material to form into desired geometry and also shape M.S.H. Bhuiyan 2012. Machining process can be grouped into three major types. There are turning, milling and drilling. Milling is a process of a cutting operation. The cutting operation can be performed by rotating the cutting tool whereas the work piece is clamped on a table. Then the feed operation is achieved by moving the work piece toward the cutting tool Trent Wright, 2000. High speed end milling process is applied for very hard material like nickel alloys, titanium alloys and others. High speed end ball milling operation is most widely used in aerospace and also nuclear reactor parts manufacturing industry A. Li, Zhao, Zheng, Pei, 2011. This is due to; the parts that used in aerospace industry must have low subsurface microstructure dislocation. During the machining, there is resultant force acting on three axes x-axis, y-axis and z-axis which known as cutting force, feed force and thrust force on the cutting tool. The cutting force exerted is varied according to nature of machining process. Inconel is known as material hard to be machined. Flank wear, notch wear and crated wear that associated with cutting force abrasiveness of Inconel 718 Çolak, 2012. Work 2 hardening is contributing factor in premature tool life reported by Zhang, Li, Wang, 2012. The other problem of machining Inconel reported is flaking problem. That is related with cyclic load exerted onto rake face of cutting tool Qian Hossan, 2007. Those problems are associated with cutting force. To overcome this problem is by changing machining strategy from conventional speed to high speed machining HSM. High speed end milling process is applied for very hard material like nickel alloys, titanium alloys and others. The machine is also used to produce a complex geometry part. High speed end ball milling operation is most widely used in aerospace and also nuclear reactor parts manufacturing industry A. Li, et al., 2011. In general, cutting speed is consider HSM when the cutting speed beyond 5000 RPM Leigh, Tlusty, Schueller, 1999. However, the most reasonable definition HSM specifically for Inconel is the cutting speed is ranging between 80 – 400 mmin Thakur, Ramamoorthy, Vijayaraghavan, 2009. HSM was claimed improve durability of cutting tool due to ability to reduce volume of removing material, hence reduce heat generated and cutting force. The study done by Qian Hossan, 2007 indicate resultant force is mostly contributed by depth of cut followed by feed rate and cutting speed. However, their study merely on experiment without simulation. From the findings, Fx is mostly contribute to the resultant force. Thus, this project is initiated to simulate the effect of cutting parameter on the resultant force and to compare with the experiment. Therefore Deform 3D software is used to simulate the high speed end milling of Inconel 718. Then the expected results will be compare with the actual experiment result which done by previous researcher. The simulation will investigate about the cutting force, where the cutting forces are affected by several of parameter. This is explaining why the application of FEM 3D software is used in order to obtain more accurate results. In this 3D Deform software, by using the simulation will investigate the force exerted on cutting tool in tree axis of direction Fx,Fy,Fz accurately. In additional, the simulations allow the complex machining operation and also there is zero cost to conduct the machining operation via simulation method. 3

1.2 Problem Statement