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MILLING PROCESS
Draen Baji
Alen Belai
Prof. dr. sc. D. Baji, University of Split, FESB, R. Bokovia bb, 21000 Split
A. Belai, University of Split, FESB, R. Bokovia bb, 21000 Split
ABSTRACT
The roughness of technical surfaces presents one of the most important criterions
relating to the choice of machining process and cutting parameters in project processing. The
following article will therefore focus on researching results of the roughness of treated
surface depending on the cutting parameters characterized to the up milling process. In order
to find the most suitable empiric model to describe the depending character of the roughness
of treated surface the following elements have been taken into consideration: cutting speed,
the depth of cut and a feedrate. The experiment with the material 2011(AlCuPbBi) has been
conducted and the central composite design of the second degree has been applied. Given
results determined by regression analysis led to the empiric equation that is used for the
purpose of the calculation of the average arithmetic roughness.
1. INTRODUCTION
Production of technical surfaces of the machine components is realized either by the
method of chips forming machining or the one without metal removal. During the machining
and the usage of machine parts the given surfaces are exposed to the effect of the various
kinds of burdening. The most important ones are mechanical and chemical burdening that
result with dilapidation of parts and corrosion. Microscopically observed, technical surfaces
are not geometrical level surfaces with the ideal smoothness but rather rough level surfaces
characterized by series of uneven spots of different forms and disposition. The dimension of
the surface roughness can affect the following elements:
the decrease of dynamic endurance,
intensified friction and dilapidation of the tribo-burdened surfaces,
D. Baji, A. Belai
the decrease of overlap of a contraction link which effects the decrease of its carrying
capacity,
speeding up the corrosion.
The roughness of the machined surface is seen through micro-geometrical
irregularities of the surface. The evaluation of the quality of machined surface is based on the
judgement of its roughness. Theoretical roughness depends exclusively on tools geometry
and applied process of machining whereas a real roughness appears as the result of
theoretical roughness though with bigger or lesser occasional roughness provoked by the
many factors. The surface roughness is influenced by the most important factors such as:
cutting parameters,
the work piece and tools' materials,
dynamic performance of machining system,
the coolant,
tool condition.
We can differ the roughness proceeded from direction of the main motion
(measurements are made in direction of machining) and the roughness came out of the
direction of feed motion (measurements are made vertically the traces of machining). The
first type of the roughness is characterized by the important activity of separation of scraps
whereas, beside the layer on the front surface, material and the geometry of tools, the cutting
speed plays the important role as well. However, the roughness dimension depends on
elastic deformation of tools, machine tool and the geometry of tools. The second type of
roughness is rather important for the surface quality and can be approximately measured on
the basis of geometry of the cutting part of tools and machining kinematics.
The main elements that determine the cutting parameters of chip forming machining
or rather the milling are as follows:
the speed of metal removal (cutting speed) vc,
depth of cut ap,
feedrate vf.
2. THE AIM, METHODOLOGY AND CONDITIONS OF EXPERIMENT
Experiment aim is to define adequate mathematical model that is used to determine
the influence of independent factors and cutting data, at surface roughness. The following
independent factors are selected: cutting speed (vc), depth of cut (ap), and feedrate (vf).. For a
concrete case, that means determination of criteria:
surface roughness: Ra = f(vc, ap, vf),
Experiments are performed in laboratory for machine tools of Faculty of electrical
engineering, mechanical engineering and naval architecture, University of Split, at universal
milling machine. The experiments are carried out by the HSS (DIN 841) milling tool as it is
shown at figure 1. For test piece material, a material 2011(AlCuPbBi) was selected, figure 2.
60
50
5/45
10
160
10
52
180
Figure 2. - Workpiece
The measurement of surface roughnes was made by Surtronic 3 instrument. The
multifactor design of the second degree has been used to carry out this experiment. Actually,
in order to learn more about the maximum or minimum of the process or its function it is
necessary to approximate it by the polynomial of the second rather than the polynomial of the
first degree.
The selected values of the cutting parameters are the following:
cutting speed:
depth of cutt:
ap,max = 2 [mm]
ap,min = 1 [mm]
feedrate:
D. Baji, A. Belai
Central composite design with empiric polynomial model of the second degree is
taken:
k
i 0
1 i j
i 1
(1)
N 2 k n0 n 20
(2)
x-i,min
x-i0
xi,max
x+i
-1,682
-1
+1
+1,682
x1 = vc [m/min]
21,991
40,055
60,475
78,539
95,033
x2 = ap [mm]
0,5
1,5
2,5
x3 = vf [mm/min]
32
90
135
190
255
Input factors
INPUT
Measured
values
Calculated
values
vc [m/min
ap [mm]
vf mm/min
Ra m
Ra m
40,055
78,539
40,055
78,539
40,055
78,539
40,055
78,539
21,991
95,033
60,475
60,475
60,475
60,475
60,475
60,475
60,475
60,475
60,475
60,475
1
1
2
2
1
1
2
2
1,5
1,5
0,5
2,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
1,5
90
90
90
90
190
190
190
190
135
135
135
135
32
255
135
135
135
135
135
135
1,73
0,67
1,82
0,81
1,95
0,99
1,98
1,11
2,88
0,84
1,07
1,25
0,91
1,62
1,17
1,11
1,14
1,18
1,15
1,15
1,73
0,59
1,73
0,59
2,07
1,06
2,07
1,06
2,86
0,78
1,12
1,23
0,86
1,72
1,12
1,12
1,12
1,12
1,12
1,12
Figure 3.- Comparison between predicted (calculated) and actual (mesured) values for
surface roughness Ra
D. Baji, A. Belai
(3)
Figure 5.- Surface roughness in dependence of cutting depth ap and cutting speed vc
(vf= 135 [mm/min])
The final value of surface roughness Ra is most dependent to cutting speed vc.
Feedrate vf also impacts surface roughness Ra. The correlation of feedrate to surface
2
roughness is presented in model through its quadratic value (v f ) and interaction with
cutting speed (vc v f ) .
D. Baji, A. Belai
5. LITERATURE
1
CEBALO, R; BAJI D.; BILI, B.: Mathematical modelling of cutting forces in the
kod tokarenja, Zbornik II, Suvremeni trendovi proizvodnog strojarstva, Zagreb, 1992.