TABLE OF CONTENT
CHAPTER CONTENT
PAGE DECLARATION
ii
ACKNOWLEDGEMENT iii
ABSTRAK iv
ABSTRACT v
TABLE OF CONTENT
vi
LIST OF TABLES viii
LIST OF FIGURES ix
LIST SYMBOLS xi
LIST OF APPENDICES xii
1.0 INTRODUCTION
1 1.1
BACKGROUND 1
1.2 OBJECTIVES
3 1.3
SCOPE PROJECT 3
1.4 PROBLEM STATEMENT
4 1.5
PROBLEM ANALYSIS 4
2.0 LITERATURE REVIEW
5 2.1
MILLING PROCESS 5
2.2 HIGH SPEED STEEL CUTTING TOOL
7 2.3
MACHINABILITY 8
2.4 SURFACE FINISH
8 2.5
PROCESS 11
2.6 TOOL WEAR
12 2.6.1
Flank Wear 12
2.6.2 Crater Wear
12 2.7
MATERIAL 13
2.7.1 Aluminium
13 2.7.2
Brass 13
2.7.3 Stainless Steel
14 2.8
CHIP FORMATION 15
2.9 CONVENTIONAL VERTICAL MILLING
MACHINE 17
2.10 FORMULATE
18 2.11
PRELIMINARY RESEARCH 19
2.11.1 A Study of The effects of Machining
19
Parameters on The Surface Roughness in the End-Milling Process
2.11.2 Effect of Machining Feed on Surface
Roughness in 6061 Aluminum 20
3.0 METHODOLOGY
21 3.1
FLOWCHART 22
3.2 SAMPLE PREPARATION
23 3.3
CONDUCTING EXPERIMENT 23
3.4 SURFACE ROUGHNESS TEST
25
4.0 RESULTS AND ANALYSIS
27 4.1
RESULT OF ALUMINUM 28
4.2 RESULT OF BRASS
29 4.3
RESULT OF STAINLESS STEEL 31
4.4 ANALYSIS
33
5.0 DISCUSSION
45 5.1
RELATIONSHIP OF SPINDLE SPEED AND SURFACE ROUGHNESS
45 5.2
RELATIONSHIP OF FEED RATE AND SURFACE ROUGHNESS
46 5.3
DISCUSSION OF SURFACE ROUGHNESS 47
6.0 CONCLUSION AND RECOMMENDATION
48 6.1
CONCLUSION 48
6.2 RECOMMENDATION
49
REFERENCES 50
APPENDICES 53
LIST OF TABLES
NO. TITLE
PAGE 4.1.1 Reading of R
a
and R
y
of aluminum at feed rate, F= 37 mmmin 28
4.1.2 Reading of R
a
and R
y
of aluminum at feed rate, F= 141 mmmin 28
4.1.3 Reading of R
a
and R
y
of aluminum at feed rate, F= 240 mmmin 29
4.2.1 Reading of R
a
and R
y
of brass at feed rate, F= 37 mmmin 29
4.2.2 Reading of R
a
and R
y
of brass at feed rate, F= 141 mmmin 30
4.2.3 Reading of R
a
and R
y
of brass at feed rate, F= 240 mmmin 30
4.3.1 Reading of R
a
and R
y
of stainless steel at feed rate, F= 37 mmmin
31
4.3.2 Reading of R
a
and R
y
of stainless steel at feed rate, F= 141 mmmin
31
4.3.3 Reading of R
a
and R
y
of stainless steel at feed rate, F= 240 mmmin
32
LIST OF FIGURES
NO. TITLE
PAGE
2.1.1 Types of Milling Operation
6 2.4.1
Standard Terminology To Describe Surface Finish 9
2.4.2 Arithmetric mean Surface Roughness, R
a
10 2.4.3
Maximum Height of Profile, R
y
R
max
10 2.5.1
Surface Roughness Range of Production Process 11
2.7.1.1 Aluminum
13 2.7.2.1
Brass 14
2.7.3.1 Stainless Steel
14 2.8.1
Types of Chips 15
2.9.1 Conventional Vertical Milling Machine
17 3.3.1
Different Types of Material Test Specimen 24
3.4.1 A Mitutoyo Precision Reference Specimen
25 3.4.2
Adjustment of Height of Stylus Detector. 25
3.4.3 Top View of Stylus Detector and Mitutoyo Precision Reference
Specimen 26
3.4.4 Mitutoyo Surface Tester SJ-301
26 4.4.1
Arithmetic Mean Value, R
a
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut on Aluminum Specimen
33
4.4.2 Maximum Height of Profile, R
y
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut on Aluminum Specimen
33
4.4.3 Arithmetic Mean Surface Roughness, R
a
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut of Brass Specimen
35
4.4.4 Maximum Height of Profile, R
y
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut of Brass Specimens
35
4.4.5 Arithmetic Mean Surface Roughness, R
a
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut of Stainless Steel
Specimen 37
4.4.6 Maximum Height of Profile, R
y
µm Versus Spindle Speed rpm at 0.2mm Depth of Cut of Stainless Steel Specimen
37
4.4.7 Graph of Arithmetic mean Surface Roughness, R
a
Versus Spindle Speed for Three Different Types of Material at Feed
Rate of 37 mmmin 39
4.4.8 Graph of Maximum Height of profile, R
y
Versus Spindle Speed for Three Different Types of Material at Feed Rate of 37
mmmin 39
4.4.9 Graph of Arithmetic mean Surface Roughness, R
a
Versus Spindle Speed for Three Different Types of Material at Feed
Rate of 141 mmmin 41
4.4.10 Graph of Maximum Height of profile, R
y
Versus Spindle Speed for Three Different Types of Material at Feed Rate of 141
mmmin 41
4.4.11 Graph of Arithmetic Mean Surface Roughness, R
a
Versus Spindle Speed for Three Different Types of Material at Feed
Rate of 240 mmmin 43
4.4.12 Graph of Maximum Height of Profile, R
y
Versus Spindle Speed for Three Different Types of Material at Feed Rate of 240
mmmin 43
LIST OF SYMBOLS
N =
spindle speed, revmin n
t
= number of teeth on the cutter
f =
chip load in mmtooth N
= Spindle speed, mmin
D =
diameter of cutter in millimeter R
y
R
max
= maximum height of profile
R
a
= arithmetic average roughness
LIST OF APPENDICES
NO. TITLE
PAGE
1 Gantt Chart PSM 1
53 2
Gantt Chart PSM 2 54
3 Technical Drawing of Test Specimen
55 4
High Speed Steel end mill 56
5 Reading for aluminum at feed rate of 37 mmmin
57 6
Reading for aluminum at feed rate of 141 mmmin 58
7 Reading for aluminum at feed rate of 240 mmmin
59 8
Reading for brass at feed rate of 37 mmmin 60
9 Reading for brass at feed rate of 141 mmmin
61 10
Reading for brass at feed rate of 240 mmmin 62
11 Reading for stainless steel at feed rate of 37 mmmin
63 12
Reading for stainless steel at feed rate of 141 mmmin 64
13 Reading for stainless steel at feed rate of 240 mmmin
65
CHAPTER 1
INTRODUCTION
