Investigation of machining parameter for face milling

operations on various materials

Members:-P.Abupakkar sidhic, (80107144002)

J.Kavirajan, (80107144019)S.Manikandan, (80107144022)

R.H.Raaj Kumar. (80107144034)

Guided by:

Mr. S.Kannan.,M.E.Associate Professor

Project description

• In our project we are going to analyze the machining parameters such as MRR,SPEED,FEED,DEPTH OF CUT and also the corresponding SURFACE FINISH for the FACE MILLING operation.

• Also we are going analyze the COST INVOLVED and MACHING TIME associated with the process.

Face Milling:

• A milling operation in which the surface of the workpiece is perpendicular to the spindle axis.

• Face milling primarily is used to mill the top surface of the part.

Face milling job and cutter

High Speed Steel properties• High Speed Steel is a multi-component alloy carbon-based steel and, as such, steel

mills manufacture HSS according to the Fe-C-X system (Iron-Carbon-X). In this system, "X" can represent one or more other elements, most commonly Tungsten plus chromium, molybdenum, vanadium, or cobalt.

• High Speed Steel exhibits a density of 8.67x1000 kg/m3 (kilograms per meters-cubed).

• A greater percentage of chromium in HSS alloys will increase its strength, while vanadium increases will improve the cutting quality and sharpness of tools and drill bits made with HSS.

• When used in tools, High Speed Steel operates at a very low thermal expansion rate of 9.7 microns per meter per degree Celsius. It also conducts heat at a very low rate.

carbide tool:

Carbide Tool Properties

• Carbide is in the range of twice that of tool steel and carbon steel. carbide is in the same range as tool steel and carbon steel.

• Tungsten carbide's low thermal expansion rate must be carefully considered when preforms are provided for grinding or EDM.

• Carbide compositions exhibit low dry coefficient of friction values as compared to steels.

• Conventional grades have sufficient resistance to corrosion-wear conditions for many applications.

Methodology Operation:

Face millingMaterialsWe are going to perform our task on the material• Aluminium, • Copper,Tool used• High speed steel • Carbide.

Parameters :Inputi. Speedii. Feed iii.Depth of cut

Find out:i. Material Removal Rateii. Machining Timeiii.Machining Cost iv.Surface roughness

specificationwork piece :

• Shape - Cube size - 32x32x32 mm

Vertical milling machine

Machine specification Mode –super mini mill

Travel: x-axis y axis z axis

406 mm305mm254mm

Table dimension: length width

914mm730mm

Spindle : speed max.motor rating

0-10000rpm11.2kw

Feed rates: maximum rapids max cutting

30.5m/min21.2m/min

Tool : capacity type max.tool diameter max. tool weight

10CT4089mm6.4kg

Accuracy : positioning repeatability

+/- 0.0051mm+/-0.0025mm

Gentral:power 15kw

Surface testing

• Surface testing machine is used by us for the measurement of all the machined surface on the material.

• The roughness should be in the range of “microns”

• The capacity of surface tester is ranges from 10 – 100 microns

Software used:

• “DESIGN EXPERT”.

Work Speed Feed Depth Of Cut Machining time

Roughness Material Removal Rate

(mm3)

Job size Machining cost

piece (rpm) (mm/min) (mm) (sec) (Microns) (mm) (Rs.)phase

1   1100 0.5 10 0.25   30X33  2   1 10 0.34   30X30  3   1.5 10 0.28   30X30  4 1900 1500 0.5 9 0.69   30X30  5 1 9 0.74   31X33  6 1.5 9 0.62   33X31  7 2200 0.5 8 1.04   33X30  8 1 7 1.23   30X30  9 1.5 8 0 .80   30X30  

10   1500 0.5 9 0.76   32X31  11   1 9 0.24   31X31  12   1.5 9 0.3   31X31  13 2500 2000 0.5 7 0.4   29X31  14 1 7 0.14   29X31  15 1.5 7 0.73   31X31  16 2500 0.5 7 0.31   31X31  17 1 7 0.84   31X31  18 1.5 7 1.1   31X31  19   1900 0.5 8 0.16   31X31  20   1 8 0.13   31X31  21   1.5 8 0.16   30X30  22   2200 0.5 7 0.13   30X30  23 3200 1 7 0.51   32X32  24 1.5 7 0.15   31X31  25 2800 0.5 7 0.18   31X31  26 1 7 0.23   31X33  27 1.5 7 0.24   31X32  

Work Speed Feed Depth Of Cut Machining time

Roughness Material Removal Rate

(mm3)

Job size Machining cost

piece (rpm) (mm/min) (mm) (sec) (Microns) (mm) (Rs.)phase λ=3

1 1200 800 0.5 16 4.85   32x32  2 1 16 3.23   31x33  3 1.5 16 3.76   31x33  4 1000 0.5 14 4.22   30x33  5 1 14 4.63   30x30  6 1.5 14 2.29   30x30  7 1200 0.5 13 4.28   33x32  8 1 13 3.82   33x31  9 1.5 12 5.02   33x31  10 1350 800 0.5 16 5.03   33x30  11 1 15 5.13   30x30  12 1.5 15 4.69   30x30  13 1000 0.5 14 3.65   32x32  14 1 14 3.45   32x32  15 1.5 14 4.04   31x33  16 1200 0.5 12 4.2   31x30  17 1 12 4.78   30x31  18 1.5 14 3.88   31x30  19 1500 800 0.5 16 6   33x32  20 1 16 3.95   32x31  21 1.5 16 3.09   31x33  22 1000 0.5 14 5.02   30x32  23 1 14 4.51   30x30  24 1.5 14 3.93   30x30  25 1200 0.5 12 4.91   32x33  26 1 12 4.03   31x32  27 1.5 12        

Work Speed Feed Depth Of Cut Machining time

Roughness Material Removal Rate

(mm3)

Job size Machining cost

piece (rpm) (mm/min) (mm) (sec) (Microns) (mm) (Rs.)phase

1 950 570 0.5 15  1.07   34X32  2 1 15  0.84   31X32  3 1.5 16  1.65   34X32  4 700 0.5 13  0.61   30X32  5 1 13  1.18   30X31  6 1.5 13  1.40   32X32  7 850 0.5 12  1.82   34X34  8 1 12  1.96   30X33  9 1.5 12  1.8   33X30  10 1200 700 0.5 13  1.56   29X33  11 1 13  1.59   29X29  12 1.5 14  1.20   29X29  13 900 0.5 12  1.26   33X32  14 1 12  1.25   32X32  15 1.5 12  1.98   33X31  16 1100 0.5 10  2.1   30X33  17 1 10  1.38   31X30  18 1.5 10  2.49   30X31  19   840 0.5 12  1.22   32X33  20   1 12  1.04   33X32  21   1.5 12  0.81   33X31  22   1020 0.5 11  1.32   30X33  23 1400 1 11  1.72   31X30  24 1.5 11  1.6   30X31  25 1300 0.5 9  1.72   32X33  26 1 10  2.33   33X32  27 1.5 10  1.28   31X33  

Work Speed Feed Depth Of Cut Machining time

Roughness Material Removal Rate

(mm3)

Job size Machining cost

piece (rpm) (mm/min) (mm) (sec) (Microns) (mm) (Rs.)phase

1 600 125 0.5 63 0.85   33x32  2 0.75 62 0.42   33x32  3 1 63 0.77   31x33  4 150 0.5 53 1.12   30x33  5 0.75 52 0.95   31x30  6 1 54 0.62   31x31  7 175 0.5 45 0.71   32x32  8 0.75 47 0.81   32x32  9 1 47 0.56   33x32  10 700 125 0.5 63 0.46   31x33  11 0.75 62 0.29   31x31  12 1 63 0.5   31x31  13 150 0.5 52 0.48   32x32  14 0.75 53 0.43   32x32  15 1 54 0.24   32x31  16 175 0.5 46 0.23   31x33  17 0.75 45 0.26   31x30  18 1 47 0.14   31x30  19 800 125 0.5 62 0.53   33x32  20 0.75 63 0.17   31x33  21 1 63 0.24   33x31  22 150 0.5 53 0.39   30x33  23 0.75 52 0.2   31x30  24 1 54 0.34   30x30  25 175 0.5 45 0.32   32x33  26 0.75 47 0.22   32x33  27 1 46 0.37   31x33  

Formulae

• MATERIAL REMOVAL RATE, MRR = f*w*d.o.c (mm3/min)

Where, f=feed in mm/min w=width of job in mm d.o.c=depth of cut in mm

Graphical analysis :aluminum in carbide tool

aluminum in carbide toolat constant speed

aluminum in carbide tool

aluminum in carbide tool

aluminum in carbide tool

aluminum in hss tool

aluminum in hss toolat constant speed

aluminum in hss tool

aluminum in hss tool

aluminum in hss tool

Copper in carbide tool

Copper in carbide tool

Copper in carbide tool

Copper in carbide tool

Copper in carbide tool

Copper in hss tool

Copper in hss tool

Copper in hss tool

Copper in hss tool

Copper in hss tool

analysis

• The MRR has to be calculated and resultant mrr graphs has yet to be drawn for analysis.

• Thus the graphical output is taken and we are going to analyse and compare the output with the help of design expert software.

Scope

• We can analyze machining parameters for face milling operation.

• We can study the cost involved and degree of accuracy associated with it.

• By doing the above analysis, we can get a ideal solution for the selection parameters of the face milling operation, so that it can be standardized.

• So surface finish ,machining cost and machining time can be improved easily.

• Hence the selection of such parameters can be made easier in industries with the help of our analysis.

DURATION:• Machining - 5 days(PRIME CNC INDUSTRY - Coimbatore)

• Surface testing - 3 days (ANNAMALAI UNIVERSITY- Chidambaram )

• Analyzing - 5 days

• Result analysis - 2 days

• TOTAL - 15 DAYS

Conclusion the Investigation of machining parameter for face

milling operations on various materials is under progress .

Thus in our project the machining parameters for the FACE MILLING operation is analysed.

• The COST INVOLVED and MACHING TIME associated with the process is analysed.

• By doing the above analysis, the selection parameters of the face milling operation is yet to be standardized.

Thank you