Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdge Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdgeTM Softwa

Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T,
4T for Surface-Rough Machining by Third Wave AdvantEdgeTM
Software Simulation.

A Graduation Project Report submitted by

Dony Irvan Siswanto
9999156136/D200122001
In fulfillment of the requirement of
One-year course in Mechanical Engineering Department,
Wuxi Institute of Technology
a part of Undergraduate study in the Department of Mechanical Engineering,
Universitas Muhammadiyah Surakarta
Towards the degree of

Bachelor of Engineering (Mechanical)

MECHANICAL ENGINEERING DEPARTMENT

WUXI INSTITUTE OF TECHNOLOGY
WUXI JIANGSU PROVINCE P.R. CHINA

2016

i

YALNI}ATION SEFT:T
This Fioal Repod has lreeo conEcted accepted axd [egali76d by supexyisor,

kno]'iog by H€ad of Mechrnical Eagilrt,ing
Technolosr and Head

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Muhanliadiyah SurakafiaComposed

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Head of Mechaniea.t F-ng-

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Unilersitas Mr,rhamrnadileh Su-alarra

{Tri Widodo Besir Riy{ili. ST, A[.Sc. Ph,D)

Iiead ofMechanical Eng Department
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(Ztung ZhBe,il[EfrB.)

FOREWORD
Thanks to Allah SWT who gives his-mercy and blessing, so author can
finish this report of Graduation Project with the planed time. Blessings and

greetings may keep to our Prophet Muhammad SAW and all his family and
friends in enforcing Dinullah on this earth.
This report is written to finish of my undergraduate study in mechanical
Engineering department of Universitas Muhammadiyah Surakarta.
In writing this report, of course, many people who have provided support
both morally and materially. Therefore, the authors would like to express
gratitude boundless to:
1.

Tri Widodo Besar Riyadi, ST., M.Sc., Ph.D as the head of
Mechanical Engineering Department Universitas Muhammadiyah
Surakarta.

2.

Mr. Zhang Zheng, M.Eng. as the head of Mechanical Engineering
Department Wuxi Institute of Technology.

3.

Dwi Agus Anggono,ST., M.Eng., Ph.D as my supervisor lecturers.

4.

Jack and May as my first Chinese friend who always help me to
study Chinese language.

5.

And all of my friends and also my family.

Finally, the author hopes this report is useful for everyone that read it.

Wuxi Jiangsu, March 2016

Author

iii

ACKNO\ryLEDGEMENTS

I would like to

to my

exf,ress my deepest gratitude
and most sincere appreciation
supervisors Mr. Jhon, vise
dean
Lecturer in mechanical

wuxi Institute of rechnorogy arso Dr.
valuabre guidance,

sup";;

also Iike to thank to Dr.

T

.**;:il:;'#,-;;:;lj#,::Ji

Widodo tsesar Riyadi as head
of Mechanical

Engineering Department Universitas
knowledge and guidanr". er*,

r

M

rrouu'rH;"::I#",ffi?;;:f;:*:

especially May Cong and Jack
which

I am in china. Lasrly,,

willi

-,,,.,-","

"J:.:Tff:;T::1lffil;:ff:

family members. Without their coitinuou!
academic study, this

re*".n

Engineering

o.:*

encouragement throughout this

**ijtJrj,and
Dony Irvan S

ABSTRACT
Surface rough-machining is one of the important process before
finishing process. For the finding the best result of rough-machining’s

quality criteria, least machining time and least remaining volume without
making worse of tool wear after roughing so need detection and analysis
optimum parameter proses without ignoring tool wear’s aspect. Cemented
Carbide flat End-mill with 2, 3, 4 Flutes used as the main case parameter
study with Al 7075 T6 as the workpiece materials, by calculation and
bring it to Third Wave Advant EdgeTM Systems Software simulation some
data become recommendation production parameters as the final
conclusion.

Key words: Rough-machining, Cemented Carbide End-mill, Al 7075
T6, Third Wave Advant EdgeTM.

ABSTRAK
Proses kekasaran permukaan merupakan salah satu proses penting
sebelum proses finishing. Untuk menemukan hasil terbaik dari kriteria
kualitas kasar-mesin ini, waktu mesin setidaknya dan volume tersisa
sedikit tanpa membuat lebih buruk memakai alat setelah hidup seadanya
sehingga perlu deteksi dan analisis optimum Proses parameter tanpa
mengabaikan aspek memakai alat ini. Semen Carbide datar End-pabrik
dengan 2, 3, 4 Flutes digunakan sebagai studi parameter kasus utama

dengan Al 7075 T6 sebagai bahan benda kerja, dengan perhitungan dan
membawanya ke simulasi Gelombang Ketiga Advant EdgeTM Sistem
Software beberapa data menjadi parameter produksi rekomendasi sebagai
kesimpulan akhir.
Kata kunci: proses kekasaran permukaan, Karbida Endmill, Al 7075
T6, Third Wave Advant EdgeTM.

v

TABLE OF CONTENTS
TITLE PAGE ...................................................................................................... i
VALIDATION SHEET ...................................................................................... ii
FOREWORD ...................................................................................................... iii
ACKNOWLEDGEMENTS ................................................................................ iv
ABSTRACT ........................................................................................................ v
TABLE OF CONTENT ...................................................................................... vi
LIST OF FIGURE ...............................................................................................viii
LIST OF TABLE ................................................................................................ ix
CHAPTER I INTRODUCTION ......................................................................... 1
1.1 Background .............................................................................................. 1
1.2 Problem Statement ................................................................................... 2
1.3 Problem Limitations ................................................................................. 3
1.4 Objective of Research .............................................................................. 3
1.5 Benefit ...................................................................................................... 3
1.6 Literature Review ..................................................................................... 4
CHAPTER II FUNDAMENTAL THEORY ...................................................... 5
2.1 General Problem in Production ................................................................ 5
2.2 Machining Parameter ............................................................................... 6
2.3 Parameter of Surface-Rough Selection .................................................... 7
2.4 Cooling System ........................................................................................ 8
2.5 Tool wear .................................................................................................. 9
2.6 Workpiece Materials ................................................................................ 10
2.7 Surface-Rough Machining ....................................................................... 11
2.8 Cutting tools ............................................................................................. 12
2.9 Tool material: Cemented-Tungsten Carbide ............................................ 15
2.10 End Mills Modeling................................................................................ 16
2.11 Optimization ........................................................................................... 17
2.12 Third Wave Systems AdvantEdgeTM ..................................................... 18
CHAPTER III METHODOLOGY RESEARCH ............................................... 21
3.1 Flow Chart of Research ............................................................................ 21

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3.2 Preparation................................................................................................ 22
3.2.1 Workpiece ......................................................................................... 22
3.2.2 Carbide Flat End-mill ....................................................................... 22
3.2.3 Other Consideration (Machine, Tool Holder, CAM Software, etc.) 23
3.3 Tool Modeling .......................................................................................... 23
3.4 Initial Approaching Data Simulation ....................................................... 24
3.5 Continuous Feedrate Data Calculation and Analyze ................................ 25
3.6 Continuous DOC Data Calculation and Analyze ..................................... 26
3.7 Continuous Parameter-Change Calculation and Analyze ........................ 26
CHAPTER IV RESULT ANALYZE ................................................................. 28
4.1 Initial Data Simulation ............................................................................. 28
4.2 Continuous Feedrate Data ........................................................................ 28
4.3 Continuous DOC Data.............................................................................. 30
4.4 Continuous Changing-Parameter ............................................................. 32
CHAPTER V CONCLUSSION .......................................................................... 34
5.1 Conclusion ................................................................................................ 34
5.2 Suggestion ................................................................................................ 35
REFERENCES
APPENDIX

vii

LIST OF PICTURE
Figure 1. Down milling with their parameter. ........................................................ 6
Figure 2. The variety of end mill cutting tools types. ........................................... 13
Figure 3. End mill attributes and terminology, (a). End mill view, (b). Cross
section view, (c). Side view [33]........................................................................... 14
Figure 4. (A). Microstructure of WC-Co tool substrate (10000X BSE Image) and
(B). EDS of area with Elemental composition ...................................................... 15
Figure 5. The 3D modeling of flat end-mills that use before simulation with (a).2flutes, (b). 3-flutes and (c). 4-flutes are done by NX 9.1. ..................................... 17
Figure 6. Statistical Variability Modeling of AdvantEdge 7.1 TM. ..................... 19
Figure 7. AdvantEdge FEM temperature presentation [39]. ................................. 19
Figure 8. Speciment of workpiece material Al-7075 T6....................................... 22
Figure 9. Flat End-mill ø8 3T (a). Tool-length view. (b). Flutes view. ................ 22
Figure 10. (a).workpiece clamped in the Chuck,(b).cutting tool with tool holder.23
Figure 11. Result of simulation . (a).temperature-contour. (b) . X-Y-Z Force. (c).
Power-Torque-Temperature. ................................................................................. 31

viii

LIST OF TABLE
Table 1.1 General equation of milling process [18]. .............................................. 7
Table 1.2 Physical properties of Al-7075 T6[29]. ................................................ 11
Table 3. Tools Specification of 3D Modeling. ...................................................... 23
Table 4. Initial data parameters. ............................................................................ 24
Table 5. Intial inputing data to TWS-Pluge simulation. ....................................... 25
Table 6. Table of Continuous Feedrate Schema. .................................................. 25
Table 7. Continuous DOC Data Schema .............................................................. 26
Table 8. Continuous Changing-Parameter. ........................................................... 27
Table 9. result of Initial data parameter calculation. ............................................ 28
Table 10. Interpolation to find feed rate value. ..................................................... 29
Table 11. Interpolation to find depth of cut. ......................................................... 31
Graph 1.Prediction result of Experiment-simulation 1. ........................................ 29
Graph 2. Prediction result of Experiment-simulation 2. ...................................... 30
Graph 3. Correlation between spindle speed, feed rate and Depth of cut ............. 32

ix