Parameter optimization for machining recycled plastic

Tan, Jared Sin Sian (2015) Parameter optimization for machining recycled plastic. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Plastic is the second highest solid waste contributor in the Peninsular Malaysia and when left to degrade naturally, it causes soil and water damaged. Therefore it should be recycled for other usage. It can be used to replace the current metal base consumable material in manufacturing laboratories for teaching and learning purposes. The metal base consumable material currently used in the laboratories causes high rate of tool wear and the chips produced are potentially hazardous. Thus, machining plastic polymer is desirable for this purpose but it causes softening and burr formation at machining edge due to unsuitable machining parameter. Therefore, it is important to determine the optimum machining parameters in order to minimize production cost and to achieve desired product quality. In this report, the Taguchi method was used for screening process and RSM box-behnken was employed for the experimentation process. The cutting parameters involved were spindle speed, feed rate and depth of cut. The responses being studied were surface roughness and machining temperature. Design Expert software were used to analyse the data by using analyse of variance (ANOVA) and to generate an optimum cutting parameter. From the experiment conducted, the optimized parameter for machining recycled HDPE plastic is by using spindle speed of 2005.21 rpm, feed rate of 1037.81 mm/min and depth of cut of 3 mm

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