Post on 11-Aug-2019
EXPERIMENTAL ANALYSIS OF MACHINING PERFORMANCE BASED ON
SELECTED CUTTING PARAMETERS FOR SMART
CNC TURNING ENVIRONMENT
SHUHAIDI BIN MOHAMAD
UNIVERSITI TEKNOLOGI MALAYSIA
EXPERIMENTAL ANALYSIS OF MACHINING PERFORMANCE BASED ON
SELECTED CUTTING PARAMETERS FOR SMART CNC TURNING
ENVIRONMENT
SHUHAIDI BIN MOHAMAD
A thesis submitted in partial fulfillment of the
requirements for the award of the degree of
Master of Engineering (Mechanical-Advanced Manufacturing Technology)
Faculty of Mechanical Engineering
Universiti Teknologi Malaysia
JUNE 2014
iii
To my beloved family, Father, Hj. Mohamad Bin Lebai Ibrahim, Mother, Hjh.
Kuntom Binti Abdul, Wife, Noor Shaliza Binti Zainal Abidin, my Sons and Daughter,
MuhammadAmirul Farish, Nur Aliya Nabila, MuhammadAmirul Hakimi, Brothers
and Sisters. Thank for all your support.
iv
ACKNOWLEDGEMENT
In the name of Allah, the most Gracious and most Compassionate
I would like to thank Allah Almighty for blessing and giving me strength to
accomplish this thesis. A special thanks to my supervisor, Dr. Aini Zuhra Binti
Abdul Kadir who greatly helped me in every way I need to go through this final
project.
I am also indebted to Majlis Amanah Rakyat (MARA) for funding my degree
of Master of Engineering. I would like to express my sincere appreciation to all of
my friends and colleagues in Kolej Kemahiran Tinggi Mara Balik Pulau for coloring
my daily live and helped me in one-way or another. Their views and tips are useful
indeed.
Deepest gratitude to my parents, all of my family, who give me a real love,
pray, support, and all they have for the continuous encouragement and patience
within this study period.
v
ABSTRACT
The purpose of this study is to analyze turning performance of Aluminium
Alloy 6061 based on selected cutting conditions such as cutting speed, feed rate and
depth of cut, in terms of acceptable range of surface roughness, with the integration
of STEP-NC as a data structure. STEP-NC, an acronym for Standard for the
Exchange of Product Model Data for Numerical Control is developed by the ISO
committee with the intention of replacing the outdated G-codes used for machine
execution. G-codes only contain point to point instructions directing the machine to
move and machine the parts with lack of intelligence. Important machining
parameters such as tolerance information, feature information and cutting tools
information are missing and cannot be utilized at CNC level. In addition, it
commonly embedded with specific extension of different vendors’ added code
depending on its controller making it lacks of interoperability. STEP-NC on the other
hand provides comprehensive data structure and may provide information such as
material properties, value of surface roughness, part feature and workingstep for the
process. In this study, dry cutting operations of a 100mm Aluminum Alloy 6061 bar
were turned into a 50mm length and 24mm final diameter based on the
combinations of various cutting parameters set using Design of Experiments (DOE)
method. The experimental results were statistically analyzed to study the influence of
cutting parameters on surface roughness. Based on this, to suit the smart CNC
turning environment, regression model were developed and were used in Graphic
User Interface (GUI) algorithm in STEP-NC for the surface roughness value output.
The outcome of this study shows that feed rate, cutting speed and depth of cut have
significance effects on the surface roughness and the best surface roughness
condition is achieved at a low feed rate 0.07 mm/rev, high cutting speed 280 m/min
and depth of cut 0.1 mm. The results also show that the feed rate has big effect on
surface roughness followed by cutting speed and depth of cut.
vi
ABSTRAK
Tujuan kertas penyelidikan ini adalah untuk mencari prestasi pemesinan
untuk kekasaran permukaan Aluminium Alloy 6061 berdasarkan memotong syarat
(kelajuan pemotongan, kadar suapan dan kedalaman pemotongan,) dengan integrasi
STEP-NC. STEP-NC menyediakan struktur data yang komprehensif dan berupaya
memberikan maklumat seperti sifat bahan, nilai kekasaran permukaan, ciri bahagian
dan langkahkerja untuk proses pemesinan yang dibuat. Dalam kajian ini, operasi
pemotongan kering (tanpa menggunakan cecair memotong) bar 100mm Aluminium
Alloy 6061 telah dilarik sepanjang 50mm panjang dan 24mm diameter akhir
berdasarkan kombinasi pelbagai parameter pemotongan yang telah ditetapkan
menggunakan kaedah Rekabentuk Eksperimen (DOE). Mengkaji hubungan yang
wujud di antara panjang, pada diameter tertentu, dan kekasaran permukaan stok bar
dalam operasi perubahan yang tidak disokong dalam usaha untuk mengurangkan sisa
persediaan dalam mengubah operasi. Konsep Rekabentuk Eksperimen (DOE) telah
digunakan untuk uji kaji perlu. Keputusan eksperimen telah dianalisis secara statistik
untuk mengkaji pengaruh parameter proses kepada kekasaran permukaan. Model
regresi telah dibangunkan dan digunakan di dalam algorithma Antara Muka
Pengguna Grafik (GUI) dalam STEP-NC bagi mendapatkan nilai output kekasaran
permukaan. Analisis varians mendedahkan dalam kajian ini adalah bahawa kadar
suapan, kelajuan pemotongan dan kedalaman pemotongan mempunyai kesan penting
kepada kekasaran permukaan dan keadaan kekasaran permukaan yang terbaik
dicapai pada kadar suapan yang rendah 0.07 mm / rev pemotongan tinggi kelajuan
280 m / min dan kedalaman potong 0.1 mm. Keputusan juga menunjukkan bahawa
kadar suapan mempunyai kesan yang besar kepada kekasaran permukaan diikuti
dengan kederasan pemotongan dan kedalaman pemotongan.
vii
CHAPTER TITLE PAGE
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF ABBREVIATATIONS xvi
1 INTRODUCTION 1
1.1 Background of the Study 1
1.2 Statement of the Problem 4
1.3 Research importance and impact 7
1.4 Objective of the Study 8
1.5 Scope of Study 9
TABLE OF CONTENTS
viii
2 LITERATURE REVIEW 10
2.1 Introduction 10
2.2 Single Point Machining 11
2.3 Cutting Tool Element for Turning 12
2.4 Aluminum Alloys 13
2.5 Surface Roughness 15
2.5.1 Arithmetical Mean Roughness (Ra) 17
2.6 Process Design and Improvement with 17
Design Experiments
2.6.1 Factorial Experiments 18
2.7 STEP-NC as a Medium for 20
Intelligent Machining
2.7.1 STEP-NC Data Model 23
2.8 Analysis of NC vs. STEP-NC program 24
2.8.1 Code arrangement 25
2.8.2 Character of code 26
2.8.3 Information in coding 28
ix
3 METHODOLOGY 30
3.1 Introduction 30
3.2 CNC Turning Operation 31
3.2.1 External Tool Holder - 34
PDJNL2020-43
3.2.2 Indexable Insert for Turning- 35
DNMG110404N-GU
3.2.3 Mitutoyo Surface Roughness 36
Tester SJ-400
3.3 Experimental Setup 38
3.4 STEP-NC Framework of Machining 43
Performance for Surface Roughness
3.5 STEP-NC Part 21 File 45
3.5.1 Part 21 File Header 45
3.5.2 Workpiece definition 46
3.5.3 Manufacturing Feature 47
3.5.4 Turning Operation 49
3.5.5 Turning Machine Tools 52
3.6 Graphic User Interface (GUI) 54
x
4 RESULTS AND DISCUSSION 56
4.1 Experimental Results 56
4.2 Part 21 File Program 57
4.3 Graphic User Interface (GUI) 61
4.4 Result of Machining Parameters 62
4.4.1 Feed Rate 63
4.4.2 Cutting Speed 64
4.4.3 Depth of Cut 65
4.4.4 Graphical Plot for 66
Surface Roughness
4.4.5 Regression Analysis Equation: 68
5 CONCLUSION AND RECOMMENDATION 70
5.1 Enhancements of STEP 70
5.2 Recommendations 72
REFERENCES
Appendices A-Others
73
78-92
xi
TABLE NO. TITLE PAGE
2.1 Surface Finish Tolerance in Manufacturing 16
Aluminum Alloy 6061
2.2 Character of code 27
2.3 The ability of NC and STEP-NC program 28
2.4 Information in NC and STEP-NC program 29
3.1 Test Matrix 40
3.2 The Range of Variables for the 41
Cutting Conditions
3.3 The cutting conditions and the groups 42
of experimental testing
4.1 Data for surface roughness by 57
using full factorial design
LIST OF TABLES
xii
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Fishbone diagram with factors that 3
influence on surface roughness
1.2 Typical composition of 4
Aluminum Alloy 6061
1.3 Difference between the current situation 6
and the use of the STEP-NC
2.1 The main cutting data/tool elements for 13
turning tool applications.
2.2 Mechanical Properties of 14
Aluminum Alloy 6061
2.3 Arithmetical Mean Roughness (Ra) graph 17
2.4 General model of a process 18
2.5 Design geometry of the 2 factorial design 19
2.6 Test matrix of the 2 factorial design 19
xiii
2.7 STEP-NC CAD/C APP/CAM/CNC 21
integration.
2.8 General description of the data model 24
and the data flow.
3.1 CNC Turning DMG CTX 310 Glidimiester 31
3.2 CNC Turning Operation 32
3.3 Technical Data for CNC Turning 33
DMG CTX 310 Glidimiester
3.4 Tool Holders for Negative Insert 34
3.5 Indexable Inserts for Turning 35
3.6 Device Mitutoyo SJ400 for 36
Surface Roughness
3.7 Definitions of Surface Roughness Terms 37
3.8 Surface Roughness compensation 38
3.9 Illustration of workpiece dimension 39
3.10 STEP-NC Framework of Machining 44
Performance for Surface Roughness
3.11 Entity of Header in Part 21 File 46
3.12 Entity of Workpiece in Part 21 File 47
xiv
3.13 Entity of Manufacturing Features in 49
Part 21 File
3.14 Facing radial and axial tool movement 50
3.15 Entity of Turning Operations in Part 21 File 51
3.16 Entity of Surface Roughness in Part 21 File 52
3.17 Turning Machine Tool 53
3.18 Tool Path representation 53
3.19 Turning machine strategy dialog (GUI) 54
4.1 Part 21 File 59
4.2 Part 21 File for Surface Roughness 60
4.3 Turning machine strategy dialog 61
in acceptable mode
4.4 Turning machine strategy dialog 62
in rejection mode
4.5 Main effects plot for Ra Vs Feed Rate 63
4.6 Main effects plot for Ra Vs Cutting Speed 64
4.7 Main effects plot for Ra Vs Depth of Cut 65
4.8 Normal Probability Plots of Residual 66
for Surface Roughness
xv
4.9
4.10
4.11
Residual Fitted Plots for Surface Roughness 67
STEP-NC Interface Algorithm 68
Data for surface roughness 69
xvi
LIST OF ABBREVIATATIONS
i Material Safety Data Sheet MSDS
ii Computer Numerical Control CNC
iii Revolution Per Minute RPM
iv Analysis of Variance ANOVA
v Machine Condition Monitoring MCM
vi Surface Roughness Ra
vii Standard for the Exchange of Product Model Data STEP-NC
viii International Standard Organization ISO
viiii Design of Experiment DOE
1
CHAPTER 1
INTRODUCTION
1.1 Background of the Study
Turning is a machining process in which a cutting tool, typically a non
rotary tool bit, describes a helical toolpath by moving more or less linearly while the
workpiece rotates. The tool's axes of movement may be literally a straight line, or
they may be along some set of curves or angles, but they are essentially linear.
Turning is also one of the most important processes in manufacturing to make
various products and parts where the material removal process is made according to
the desired design and shape. It may also produce accurate and precise results
compared with other processes.
The modern technologies of turning are directed toward development of
optimization tables that list specific feed rates, spindle speeds, and depths of cut for
different materials. These tables then will be the standard used in industry as a source
2
of reference, when making various turning operations from one job to another where
the machining parameters of each may be quite different. The time, material, and
tooling costs associated with the experimental steps needed to be properly planned
according to the appropriate machining parameters to eliminate high setup costs as
well as to sustain the product quality.
In the process of machining, surface roughness (Ra) is very important
indicator to ensure good quality products. Surface roughness is a result very critical
in the sense that in some industries such as medical implant, surface roughness can
result in injury to the user if the Ra value exceeds a certain limit. To ensure that Ra is
within range, various factors need to be considered such as machining parameters,
workpiece shape and material, cutting tools properties and also cutting phenomena
such as vibrations, cutting force and chip formation. The cause and effect diagram
shown in Figure 1.1 highlights these factors that need to be considered in order for
manufacturers to maximize their production.
To suit the smart CNC turning environment, one way to mathematically
represent the relationship of the abovementioned parameters is by using Design of
Experiment (DOE) techniques. DOE is used to generate models, including regression
in order to get a model that generates an accurate prediction of surface quality which
were used in STEP-NC and gives a robust mathematical representation of the related
parameters. Such models will then leads to optimization and efficient machining
process.
3
Figure 1.1 : Fishbone diagram with factors that influence on surface roughness [1]
Aluminum Alloy 6061 is used as a main material because of its good
mechanical properties. It also exhibits good weld ability [2]. It is one of the most
common alloys of aluminum for general purpose use. Originally called "Alloy 61S,"
it was developed in 1935. This material commonly used for wide purposed such as
construction of aircraft structures, yacht construction, including small utility boats,
automotive parts such as wheel spacers and for the manufacture of aluminum cans
for the packaging of foodstuffs and beverages. It is known as a precipitation
hardening aluminum alloy, containing magnesium and silicon as its
major alloying elements as shown in Figure 1.2.
4
Component Amount (wt.%)
Aluminium Balance
Magnesium O.S- 1.2
Silicon O A o (B
Iron Max. 0.7
Copper O. 15-0.40
Zinc Max. 0.25
Titanium Max. O. 15
Manganese Max. O. IE
Chromiium 0.04-0.35
Others 0.05
Figure 1.2 : Typical composition of Aluminum Alloy 6061 [2]
1.2 Statement of the Problem
The quality of machined components is evaluated by how closely they adhere
to set product specifications of length, width, diameter, surface finish, and reflective
properties. For machining, surface roughness is harder to attain and track than
physical dimensions are, because relatively many factors affect surface roughness.
Some of these factors can be controlled and some cannot. Controllable process
parameters include feed rate, cutting speed, tool geometry, and tool setup. Other
factors, such as tool, workpiece and machine vibration, tool wear and degradation
and workpiece and tool material variability cannot be controlled as easily. There are
5
usually based on experience and trial and error to obtain suitable cutting data for
each cutting operation involved in machining a product. Therefore, such traditional
machining practices will results to high setup time with less efficiency
In traditional machining, lack of information available that can be obtained
during machining where during machining process, machine tools are executed based
on simple point to point geometry data by means of NC codes known as ISO 6983
(G-code). It contains low level information and has been used for more than 60
years. It consists of geometric coordinate information in (point to point form)
directing the machine to move and machine the parts. This code lacks of other
important machining parameters such as tolerance information, feature information
and cutting tools information. In addition, it commonly embedded with specific
extension of different- vendors added code depending on its controller. Realizing
these drawbacks, ISO committees have been working to improve this existing
standard. The outcome of this international effort leads to the development of a new
standard called Standard for the Exchange of Product Model Data for Numerical
Control (STEP-NC) or also known as ISO 14649 was published.
With the introduction of STEP-NC, high level data information such as
material properties, parts tolerances, part features and surface roughness value to be
incorporated during machine execution. STEP- NC may recognize part feature,
surface roughness, dimension of the stock part and material properties at CNC level
and therefore enables further optimization and analysis to be conducted. It enables
bi-directional data flow making it an intelligent machining platform. It may also
provide interoperability as it eliminated the vendor specific extensions. Figure 1.3
illustrates the difference between the traditional machining practice and STEP-NC
interface. This will leads to a smart CNC turning environment.
6
Current situation STEP-NC interface
ISO 6963
1
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Ivender specific
format
INC controller
-low level information- simple movement- simple switching- no high level curve
format- no geometry item
information- vendor specific
extensions- for one machine too I and
one machine setup only
C4DCAM
s t e p ^
#1 =WDrkp ecei’demo1,.. #3,.): #2=aiis2pl3cefir enl3d{....); #3=Hock(_.>;
4 = w d r k p la r i{ . . . { £ 5 ,# S ))
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ng{._);
ncNC planning and design
shop floor
NC controller
+ high level information + object oriented description + use of STEP geometries + vendor neutral + processable on different
mac hi nes + enables bidirectional data
flow
Figure 1.3: Difference between the current machining situation and the use of the
STEP-NC [4]
Since then, a lot of effort and studies has been performed to enhance the
capability of this new standard. For example, an enabled machine condition
monitoring system for adaptive execution of a STEP-NC based optimization
controller has been realized and developed for feed-rate optimization [3]. Therefore,
in supporting such effort, this study intends to portray how the comprehensive data
provided by STEP-NC can be utilized at CNC level. For example, in traditional
machining, in monitoring the machining parameters with respect to the desired
surface roughness values, machined parts were first measured to obtain the Ra values
using a surface roughness instrument. Following that, a series of analysis should be
performed in order to obtain the right parameters for the right surface roughness.
These procedures are very time consuming, reduce the machining efficiency and
high in cost. With the use of STEP-NC, the values of Ra after machining can be
monitored and embedded with a developed algorithm.
7
1.3 Research importance and impact
The importance of this research is to bring awareness of an advanced
machining environment especially towards local manufacturing industry in Malaysia.
STEP-NC is the first NC program that contains details about the steps to complete
machining and easily understood by the user. It contains a description of tools,
machining strategy and machining processes that are not available in ISO 6983
before. So, any loss of information to abstract movements and switching information,
as in the case of conventional programming interfaces, is avoided [4]. As STEP-NC
can bring ease and agile data transfer, it is an opportunity to develop a system that
may replace the old system thus it makes variety in manufacturing industry.
Other significant impact of this research is to promote the advantages of
STEP-NC. This will open an opportunity to hold cooperation between researcher in
universities, manufacturing industries, users, software developers and CNC vendors.
Consequently, this research brings understanding to ISO 14649 fundamental and
concept behind it, as the standard is the brain to the key in developing software to
generate STEP-NC code. ISO 14649 part program is generated by clicking the
generate code button. The program is based on workpiece and machining working
steps in a physical file text. This file text can be saved to a selected directory folder
and can be edited by the user based on manufacturing features, strategies and tools.
When the user has finalized the part program, it can be sent to the machine controller
that tallows bidirectional data flow. Apart from that, the study aims to promote the
understanding of ISO 14649 fundamentals and concepts, as the standard that can
store various machining data in executing CNC machines via STEP-NC codes and
instructions.
In the future, STEP-NC promise great profits to current manufacturing
environment where it does not have to depend on CNC machine functions that need
post-processors. The vision is to have a STEP-NC Controller that is open, intelligent
and interoperable (Xu et al., 2006). In this way, G & M code is not necessarily
needed to be generated continuously to suit various kind of CNC controller
functions. Data transfer can also be done at anytime and anywhere. With STEP-NC,
8
the process cycle of machining operation can be reduced. Correction of machining
data can be done directly at shop floor stage where the STEP-NC controller is
success to develop. Hereafter, data can be shared all over the world in a more
effective way. STEP-NC controller not only can machine part due to the machine
movement but it will provide comprehensive information for better understanding of
understand of the overall machining process which includes the feature information,
its geometry, tolerances, cutting tools data as well as its machine technology.
Since STEP-NC potentials have attracted a lot of research interests in the
recent years, it could may become reality and give a lot of benefits such as ease of
use in terms of programming data which will be used on different types of CNC
machines or vendors, and it also would save consumers or manufacturing industry in
terms of cost, manufacturing time and delivery and also will enhanced profit for the
manufacturing industry.
1.4 Objectives of the Study
While there are many machining optimization parameters that have been
developed and tabulated, an area that has been overlooked is to find the best or
suitable parameters of speed rate and cutting speed for machining Aluminum Alloy
6061. Thus, the choice of optimized cutting parameters becomes very important to
control the required surface quality.
At the same time, the emergence of STEP-NC found to be a right solution
towards optimization and knowledge utilization during machining. Therefore, the
objective of the study is:
i. To determine optimum cutting parameters for better machining performance
utilizing high-level data (STEP-NC).
9
1.5 Scope of Study
In the course of this study, some scope has been identified to achieve the
research objectives and as a passing reference in this study. With the research
specialization, this study can be done better and more organized. Among the scope of
this study are:
i. Utilize high-level data (STEP-NC) for development of smart CNC turning
environment
ii. Analyze machining performance of an Aluminum Alloy 6061 workpiece
material for better surface quality such as surface roughness
iii. Identify suitable cutting parameters such as cutting speed, feed rate, depth of
cut and workpiece dimension
iv. Conduct experimental analysis based on design of experiments (MINITAB)
to suit smart turning environment.
73
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