INVESTIGATION ON THE EFFECT OF CUTTING...
Transcript of INVESTIGATION ON THE EFFECT OF CUTTING...
INVESTIGATION ON THE EFFECT OF CUTTING
PARAMETERS ON MACHINING OF ALUMINIUM USING
5-AXIS MACHINING
SHUKRI ZARIZI BIN KAMARUZAN
B050810126
UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2011
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
INVESTIGATION ON THE EFFECT OF CUTTING
PARAMETERS ON MACHINING OF ALUMINIUM USING
5-AXIS MACHINING
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process)
by
SHUKRI ZARIZI BIN KAMARUZAN
B050810126
FACULTY OF MANUFACTURING ENGINEERING
2011
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Investigation on the Effect of Cutting Parameters on Machining of Aluminium Using 5-Axis Machining
SESI PENGAJIAN: 2010/2011 Semester 1 Saya SHUKRI ZARIZI BIN KAMARUZAN mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk
tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran
antara institusi pengajian tinggi. 4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Disahkan oleh:
Cop Rasmi: Tarikh:
Alamat Tetap: No. 15 Kampung Parit Kudus,
82000 Pontian,
Johor Darul Ta’zim. Tarikh:
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as
a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Manufacturing Process) with Honours. The members
of the supervisory committee are as follow:
………………………………
Main Supervisor
(PROF. DR. MOHD RAZALI B. MUHAMMAD)
………………………………
Co-Supervisor
(DR. MD NIZAM B. ABD. RAHMAN)
DECLARATION
I hereby, declared this report entitled “Investigation on the Effect of Cutting
Parameters on Machining of Aluminium Using 5-Axis Machining” is the results of
my own research except as cited in references.
Signature : ……………………………....
Author’s Name : SHUKRI ZARIZI B. KAMARUZAN
Date :
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ABSTRAK
Pengisar ialah bentuk paling biasa dalam memesin, proses pembuangan bahan ini
dilakukan bagi mewujudkan pelbagai bentuk dengan membuang jauh bahan yang
tidak dikehendaki. Sekarang ini, mesin CNC lima-paksi semakin meningkat naik
kerana boleh menyelesaikan sebuah bahagian yang kompleks. Oleh kerana itu,
projek ini akan memfokuskan kepada bahagian dinding atau sisi mata alat dengan
menggunakan mesin pengisar lima paksi. Membuat model (CAD) dan
pengaturcaraan (CAM) telah dibuat menggunakan perisian CATIA. Terdapat tiga
analisis utama akan dibawa keluar dan dianalisis. Iaitu kekasaran permukaan,
perubahan dimensi dan kehausan mata alat. Bahan mentah akan dipakai ialah
Aluminium dan menggunakan mesin DMU 60 MonoBlock. Dalam kekasaran
permukaan dan perubahan dimensi keadaan yang akan mempengaruhinya seperti
kadar kelajuan pusingan dan kadar suapan akan di analisis menggunakan kaedah
Rekabentuk Ujikaji (DOE) dengan cara Permukaan dengan Aturan (Response
Surface Methodology). Selain itu, kesan pada mata alat juga akan disiasat selepas
pemesinan dibuat. Dalam projek ini terdapat dua jenis alat pemotong akan digunakan
yang berbeza panjangnya. Penyebab kehausan mata alat seperti kadar kelajuan
pusingan dan kadar suapan setelah menjalankan proses pemesinan juga akan
dianalisa. Sementara itu, analisis akan dibuat menggunakan beberapa radas seperti
kekasaran permukaan penguji mudah alih (portable surface roughness tester), mesin
pengukuran koordinat (CMM), dan microskop optik (optical microscope).
Keputusannnya, kadar kelajuan pusingan dan kadar suapan telah member kesan
kepada permukaan kekasaran, ketetapan dimensi dan kehausan mata alat.
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ABSTRACT
Milling is the most common form of machining; a material removal process in which
can create a variety of features on a part by cutting away the unwanted material.
Nowadays, CNC machine of five axis machining become popular in order to solve a
complex machining of part. Hence, in this project will focus on flank milling using
five axis machining. The design modelling (CAD) and the machining programming
(CAM) have been developing using CATIA software. There were three main
analysis was carried out and analyzed. Namely the surface roughness, dimension
variation and tool wear. The raw material used is Aluminium and the machining
done using DMU 60 MonoBlock. In surface roughness and dimension variation the
influence happen will be analyze using Design of Experiment (DOE) method which
is Response Surface Methodology (RSM). Besides that, the effect happen in the tool
also has been investigated after the machining done. Meanwhile, the analysis was
successfully done using some apparatus such as portable surface roughness tester,
Coordinate Measuring Machine (CMM), and optical microscope. As the result, the
parameter such as spindle speed and feed rate is given influence to the surface
roughness, dimensional accuracy and tool wear.
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ACKNOWLEDGEMENT
First and foremost, praise to god that give me some health and ability to be here
preparing my Final Year Project with full of my intension of learning. With His
fortune and prosperity, I am finished project besides learning the experiences before I
am facing my reality of working life. I would like to express my deep and sincere
gratitude to my lecturer for the valuable guidance and advice; Prof. Dr. Mohd Razali
B. Muhammad, he has inspired me greatly to work in this project. Also not to forget
Dr. Md Nizam bin Abd. Rahman, my co-supervisor with his wide knowledge and
logical way of thinking has been beneficial for my. With this two person
understanding, encouraging and personal guidance have provided a good basis for
my project including completion of this PSM. Besides that, I would also like to thank
all of the people that involved both directly or indirectly helping me during the
project session and preparing this report successfully. These people are including
lecturer and staffs in UTeM, my fellow friends, partners and all people that
contribute in supporting me during this project from the beginning to the end of the
program. I would also like to thank the authority of UTeM for providing me with
good environment and facilities throughout the day of project. Finally, an honourable
mention goes to my family especially my beloved parents, with their understandings
and moral supports on me throughout the project and also in completing this report.
Without helps of the particular that mentioned above, I couldn’t complete the tasks
successfully. Thank you so much.
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DEDICATION
With honest, special thanks dedicated to my beloved parents, my PSM supervisor
and UTeM community, and my fellow friends and also to every single person who
has provide the opportunities with all your love, patience and understanding.
All your blessing will be granted
Thank You.
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TABLE OF CONTENT
Abstrak i
Abstract ii
Acknowledgement iii
Dedication iv
Table of Content v
List of Tables viii
List of Figures ix
List Abbreviations xi
1. INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 3
1.3 Objective of Project 4
1.4 Scope of project 4
1.5 Structure of the Report 6
1.6 Activity Planning 7
1.7 Summary 7
2. LITERATURE REVIEW 8
2.1 The Milling Process 8
2.2 Milling of Aluminium 11
2.3 Surface Roughness 12
2.4 Cutting Tool and Tool Wear 15
2.5 Dimensional Variation 18
2.6 CAD/CAM 19
2.7 Design of Experiment (DOE) 20
2.8 Summary 21
3. METHODOLOGY 22
3.1 Introduction 22
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3.2 CAD/CAM 23
3.3 Squaring Process 29
3.4 Five Axis Milling Machine 29
3.5 Work piece Material 31
3.6 Tool Selection 31
3.7 Parameters for DOE 32
3.8 Analysis 34
3.8.1 Dimensional Variation 34
3.8.2 Surface Roughness 36
3.8.3 Tool Wear 37
3.9 Summary 38
4. RESULT 39
4.1 Introduction 39
4.2 Surface Roughness 40
4.3 Dimension Variation 41
4.4 Tool Wear Analysis 42
4.5 Design of Experiment (DOE) 46
4.5.1 Fit Summary 47
4.5.2 ANOVA 50
4.5.3 Interaction Plot 52
4.5.4 One Factor 53
4.5.5 Optimization 55
4.6 Summary 57
5. DISCUSSION 58
5.1 Introduction 58
5.2 Discussion 59
5.3 Summary 61
6. CONCLUSION 62
6.1 Conclusion 62
6.2 Future Works 63
vii
REFERENCES 64
APPENDICES
A Gantt Chart for PSM 1
B Gantt Chart for PSM 2
C Detail Drawing
D ISO for Surface Roughness
E Surface Roughness Result
F CMM Result
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LIST OF TABLES
2.1 Physical properties of aluminium alloy at room temperature
(Kalpakjian and Schmid, 2006) 11
3.1 Properties of aluminium alloy at room temperature
(Kalpakjian and Schmid, 2006) 31
3.2 Matrix of the RSM 33
3.3 Machining parameter 33
4.1 Data for surface roughness analysis 40
4.2 Show the measurement result get from CMM 41
4.3 Indicated the result of dimension variation and was calculate
using the percentage error 42
4.4 Images of the tool wears captured by optical microscope. 43
4.5 Overall data accumulated in Design Expert data sheet 46
4.6 The result of Fit Summary Analysis for surface roughness 48
4.7 The result of Fit Summary Analysis for dimension variation 49
4.8 The result of ANOVA for surface roughness 50
4.9 The result of ANOVA for dimension variation 51
4.10 Constraints and Solution for DOE 55
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LIST OF FIGURES
1.1 Project flow chart 5
2.1 Six kinds of configurations for five axis machine
(Lin and Koren, 2000). 9
2.2 Five axis milling operation (Baptista and Antune Simoes, 1999) 13
2.3 Roughness and waviness profile (Kalpakjian and Schmid, 2006) 13
2.4 Parameter affects surface roughness (Benardos and Vosniakos, 2003) 14
2.5 Tool with a severe built-up layer (Rivero et al. 2008) 17
2.6 The process of experiment (Paul and Robert, 2002) 20
3.1 Flow chart from CAD until NC code 23
3.2 Part or model selected in isometric views 24
3.3 Stock, plane, and machining reference were assembled together 25
3.4 Simulation of roughing process 26
3.5 Completed part and the simulation 27
3.6 The programming code (not fully) 28
3.7 The conventional milling machine 29
3.8 DMU 60 MonoBlock machine 30
3.9 Part name of the cutting tool 32
3.10 Wenzel Model LH54 35
3.11 Portable surface roughness testers 37
3.12 Optical microscope 38
4.1 Part and the line was investigate 39
4.2 Broken edges happen on the machining setup number 2nd (left)
and 10th (right) 45
4.3 Shows the interaction result between feed rate and surface roughness
to the surface roughness value 52
4.4 Shows the interaction result between feed rate and surface roughness
to the dimension variation value 53
x
4.5 One factor of spindle speed (left) and one factor of feed rate (right)
to Surface Roughness 54
4.6 One factor of spindle speed (left) and one factor of feed rate (right) to
Dimension 54
4.7 The graph was showed the relationship between feed rate and
spindle speed to the surface roughness 56
4.8 The graph was showed the relationship between feed rate and
spindle speed to the dimension variation 57
5.1 Feed rate part need to control 60
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LIST OF ABBREVIATIONS
Al - Aluminium
ANOVA - Analysis of Variance
CAD - Computer Aided Design
CAM - Computer Aided Manufacturing
CMM - Coordinate Measuring Machine
CNC - Computer Numeric Controlled
DOE - Design of Experiments
FWC - Floor-Wall and Ceiling
HSS - High speed steel
ISO - International Organization for Standardization
MM/MIN - Millimetre per Minute
NC - Numerical Control
PSM - Projek Sarjana Muda
R - Cylindrical cutter
Ra - Arithmetic average deviation
RPM - Revolutions per minute
Rq - Root-mean-square-roughness
RSM - Response Surface Methodology
V5 - Version 5
3D - Three-Dimensional
CHAPTER 1
INTRODUCTION
1.1 Background
Metal cutting is defined as the removal of metal chips from a work piece in order to
obtain a finished product with desired attributes of size, shape, and surface
roughness. Metal cutting process can be done by using several processes such as
machining, turning, grinding, threading and other. So this metal cutting is the most
significant in manufacturing processes. In machining contexts, the milling is some of
the processes used to remove material to produce a high quality of product.
Milling is typically used to produce parts that are not axially symmetric and have
many features, such as holes, slots, pockets, and even three dimensional surface
contours. Others application of milling is the fabrication of tooling for other
processes. An example of this is complex three-dimensional (3D) object such as
mould making and aircraft turbine making. In Computer Numeric Controlled (CNC),
milling is the one from several types of milling machine. This CNC machines now
have been used in our industries such as aerospace, automotive, fabrication,
instrumentation, machinery, and also mould and die making. Nowadays, this CNC
machine from 3-axis and have been improved to 5-axis. Thus, 5 axes milling
machine adding two more (A;B) axis in addition to the three normal axis (X;Y;Z).
The axis is determined by the modular or combination of axes in the respective
machine tools.
Milling is the indicated process when needed to make all the other part that cannot be
made on the lathe machining. The demand of low tolerances and better quality
product has forced in manufacturing industry to continuously progress in quality
control and machining technology. In 5-axis machining, there are two different
methods of tool approach. The first method is by using the face of the tool which
occurs in most machining processes and the second method is by using the body, side
or shaft of the cutting tool or also known as flank milling.
The 5-axis CNC milling machine is used for produce 3D contours. This machine
used typical program alphanumerical data coded. The data represent relative motion
position between cutting tool and a work piece. This machine actually flexibility to
manufacture a complex or impossible jobs. From this benefit, this machine become
widely use in the heavy industry and any application. The major components of this
machine are drive units, sliding system, and machine control unit.
This 5-axis milling machine can remove the material to produce a high quality
product. The important thing to produce the high quality product is the input
parameter and the output characteristics. The factors of input parameter that will
influence the final surface roughness; such as spindle speed, feed rate, and depth of
cut on control the cutting operation (Boothroyd and Knight, 1989). A product’s
quality is harder to attain and track than physical dimensions, because relatively
many factors affect product surface. Some of these factors can be controlled and
some could not.
Nowadays, in the industries, the dimension accuracy and the surface finish need
special attention to produce high quality product. In this project, it will investigate
about the surface roughness value and dimensional variation on flank cutting
condition. Most of the aerospace parts are thin and consist of pockets, flanges, and
arc shapes or contours. Flank milling or machining using the body of the tool is very
important and needs to focus and concentrate with full attention. After the
experiment was done, the effect of tool wear on the face and the body of the tool also
can be study. The contour that will be study is the curved shape profile.
1.2 Problem Statement
This 5-axis CNC machine is a new technology for our industries. In getting the high
of quality product from this machine is needed to studying about the surface
roughness of the product. Most of the works or research so far has focused on the
face milling. While the flank milling can provide large productivity gains for such
class of surfaces as are found in blades, fans, turbines and other engineering objects.
With flank milling the surface can be cut with a single pass, which is more efficient
than a point milling method. Thus, this project was initiated to investigate the flank
milling machining performance with certain sets of spindle speed, feed rate, and also
to investigate the effect on tool wear.
Considering the existing researches in flank milling, most of research spent more
attention on the tool path generation, positioning, and optimization of machining
accuracy. It is quite difficult to see a research in flank milling that concentrating on
the end result of the machining as what had been presented in this project such as
effect tool wear, surface roughness and dimensional accuracy. The number of
research found for analysis mentioned was done in five axis machining and were
used a different parameter setups.
The relationship between parameter and tool is very close, an example tool life
increase rapidly as the cutting speed increase. The tool life will be affected when the
cutting speed is slow. When the cutting speed is decreases, the force applied on the
product is high and the tool wear will effect quickly. Tool life is often involved with
the tool wear reaction that affects the product quality especially on the product
surface finish. Beside that there are more differences in tool life for different
material.
1.3 Objective of Project
The purposes of this project are:
a) To investigate the influence of spindle speed and feed rate on the surface
roughness value and dimensional variation to the flank cutting condition.
b) To study the effect of the tool wears on the face and body of the tool when
cutting is performed in flank milling for a curved shape profile.
c) Apply the Design of Experiment (DOE) method in terms of spindle speed and
feed rate.
1.4 Scope of project
Using the 5 axis CNC milling machine, this project will analyze the surface
roughness and dimensional variation of the curved shape part. During machining,
will use different value of spindle speed and feed rate. The project will use Design of
Experiment (DOE) method where the type of design is Response Surface
Methodology (RSM). Before the project started, parameter that wants to use will be
identified and the part modelling will be assisted as known as Computer Aided
Design (CAD) using CATIA software. Then the modelling will go through to
machining programming called Computer Aided Manufacturing (CAM) also using
the same software. Machining test for this project was carried out by using DMU 60
MonoBlock multi-axis CNC machine. The material used is Aluminium and the
cutting tool use has a 25mm cutting length. After done machining, the machined part
will be analysed about the surface roughness using portable surface roughness tester,
dimension variation using Coordinate Measuring Machine (CMM), and tool wear
using optical microscope. The result from this project will be record and analysed.
The flow chart of this project is at the Figure 1.1.
Figure 1.1: Project flow chart.
Define an objective of experiment
Part selection and Design of Experiment (DOE) application
Literature review and searching material
Modelling preparation using CATIA / CAMCAM
Running experiment using DOE set-up
Creating a programming with parameter according to DOE result
Start machining material
Analysis product: 1. Tool wear 2. Surface roughness 3. Dimension variation
Project Report
Tool path verification using
VERICUT software
Data collection and analysis using DOE
No
Yes
1.5 Structure of the Report
This report is for completing the ‘Projek Sarjana Muda’ (PSM) with contain chapter
1 until chapter 6 only. The chapter 1 until chapter 3 was done by last semester and
for PSM 2 on this semester consist of chapter 4 until 6.
Chapter 1: This chapter was included about the title of this project, problem
statement, objective of this project, and scope of the project. This will be a guideline
for complete the PSM. In this chapter, there are three objective of this project that
should be study and find.
Chapter 2: This will define about the literature review about the five axis milling
machine. All the process parameter using this machine from the journals and books
provided. In the end of this chapter is a summary of literature review is also
provided.
Chapter 3: Describe an experimental method of this project including Design of
Experiment (DOE), experiment flow, experiment set up and equipment, and
technique used. Introduction on some method and approach in selecting an optimize
parameters for this experimental research also stated in this report. The conclusion of
this chapter would interpret as research flow along this research. The method for this
project can see in Figure 1.1
Chapter 4: In this chapter was describing about the result from the analysis data. The
data got then will use in Design Expert software. This software then will generate the
Graph, Summary, Interaction Plot, Main Effect, and Optimization. Meanwhile, the
parameter was used in this project such as spindle speed and feed rate can see from
the graph and the best setup also can know. Furthermore, this chapter provides
interpretation of experiment result.
Chapter 5: Describe about the response such as surface roughness, dimension
variation, and tool wear. All the response will discuss in this chapter, and will
describe the initial cause. Additionally, the solutions to prevent the cause also have
been described.
Chapter 6: This chapter will describe a conclusion of this research including
interpretation of overall research flow. The overall research objectives, scope,
findings and discussions also conclude in this chapter. Finally, this chapter provides
recommendation of future works.
1.6 Activity Planning
This activity planning will show by using the Gantt chart show in Appendix A and
Appendix B. This will show about the time and the work that have been done in PSM
1 and PSM 2. This Gantt chart is a planning or scheduling operation involving in this
project. By using this chart, it is easy to understand, even though it may contain
information.
1.7 Summary
This chapter is important to run this project. This project had described about the
problem statement, objective, scope, the structure of this report. The objectives of
this project need to achieve after done this project. The objective of this project had
three; firstly, investigate about the surface roughness and dimension variation with
using defined parameter setup, secondly, investigate about the tool wear and lastly
applying the DOE method. Meanwhile, the project also had a scope to focusing in
the certain part that has been described.