A Study Of The Influence Of Cutting Parameter On Surface Roughness And Surface Morphology In High Speed Milling

Ahmad Mustafa, Ali (2013) A Study Of The Influence Of Cutting Parameter On Surface Roughness And Surface Morphology In High Speed Milling. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

In metal cutting and manufacturing industries, surface finish of a product is very crucial in determining the quality. Good surface finish not only assures quality, but also reduces manufacturing cost. Surface finish is important in terms of tolerances, it reduces assembly time and avoids the need for secondary operation, thus reduces operation time and leads to overall cost reduction. Besides, good-quality machining surface is significant in improving fatigue strength, corrosion resistance, and creep life. High-speed machining (HSM) has emerged as a key technology in rapid tooling and manufacturing applications. Compared with traditional machining, the cutting speed, feed rate has been great progress, and the cutting mechanism is not the same. In this study, the main objective is to study the effect of cutting parameter on surface roughness, hardness and surface morphology of mild steel in high speed milling operation. Different cutting parameters have different influential on the response. In the experiment conducted in this study, 3 factors which are spindle speed, feed rate and depth of cut and 3 level of cutting parameter were used. Taguchi optimization method was used to optimize the machining parameters, in which a response variable can be identified. The standard orthogonal array of L9 (33) was employed in this research work and the results were analyzed by using signal to noise (S/N) ratio response analysis and analysis of variance (ANOVA) to identify the influence response. From the results, it is concluded that higher spindle speed, high feed rate and medium depth of cut produced better surface finish. The optimum combination of spindle speed, feed rate and depth of cut in this case were 20000rpm, 2000mm/min and 0.3mm, which produced average surface roughness 0.263μm. The influence of cutting parameter used in this study toward the subsurface hardness and surface morphology was found not significant.

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