Feedrates Optimization And In Ball End Milling Of Mild Steel

Noor Haznil Ikmal , Abdul Jalil (2010) Feedrates Optimization And In Ball End Milling Of Mild Steel. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Nowadays, milling is the most effective, productive and flexible-manufacturing method for machining complicated surfaces. Ball End Mill is the one of the millings tool. It also can used in machining the geometrical shapes of product or manufacture of free form surfaces such as dies and moulds, and various parts, such as aerospace components. The ball end milling is, however, less efficiency than the flat end milling. It is important to optimize the feedrate that gives the maximum material removal rate constrained by an allowable surface roughness. The purpose of this project are to study the optimization of the feedrate in Ball End Mill in order to consider the generated-scallop effect by the ball-end cutter, to optimum quality and efficiency in order to improve scallop height of machining in ball end milling and to obtain the scallop height after done sweeping process in ball end milling process. Hence, to find out the solution, this project done based on the study of the method of several journals. This study also is to discover the suitable feedrates to produce the best surface roughness of mild steel. The others method use in the study are modelling of the process using CATIA, basic machining of CNC Milling Machine, and measurement for the surface roughness which using ‘surface roughness tester’. Above all, this study uses the Design of Experiment (DOE) method in analyzing the result. Finally, the proposed methods are applied on workpiece (mild steel) and results are presented. The result is shown that the lowest step over, feed and angles is the lowest of scallop height (lowest Ry value).

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