Feasibility Study Of Adoption Pulsation Coolant On Cutting Force During End Milling Aluminium 6061

Wong, Pui Kei (2019) Feasibility Study Of Adoption Pulsation Coolant On Cutting Force During End Milling Aluminium 6061. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Aluminium alloy 6061 is a widely used in aerospace industry, automobile, and engineering applications due to its special characteristic of high specific strength, high resistance to corrosion and light in weight. This material is well known as good machinability. However, the gummy feature creates a problematic issue of build up edge (BUE) formation during the cutting process. This research is focused on the cutting force when machining Aluminum alloy 6061 under different coolant condition. A new strategy of pulsation coolant was introduced by taking advantage of shock wave formation of water stream which can minimize BUE formation. The study is to investigate the possibility of drawback on cutting force. The response surface methodology (RSM) using the Historical data design was used to conduct the experiment and analyse the relationship between control variables and responses. A total of 29 experiments were conducted with two numerical and one categorical factor at three levels each. The investigated milling parameters were cutting speed (150 - 200 m/min), feed rate (0.15 - 0.35 mm/tooth), and coolant system (pulsation, flooded, dry). The CVD coated of TiAlN ball nose tungsten carbide (WC-10%Co) cutting tools were tested throughout this study. Cutting forces during end milling operation were measured and recorded by dynamometer Kistler. ANOVA was used to identify the significant effect of the factors on the response. Based on the analysis, the feed rate was found to be the most significant factor for the resultant force. However, cutting speed and coolant system was found to be not significant. The mathematical models were developed for the response of resultant force with an average error of 14.8 N (8.87%). The error is considered a strong correlation with the R2 value of 0.71. The optimum (lowest) responses were achieved when the Vc = 200 m/min, fz = 0.15 mm/tooth, for the resultant force of 114N, 107N and 119N during pulsation, dry and flooded respectively. From the research, it can be concluded as the pulsation strategy will not affect on cutting force.

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