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This project focuses on the prospect of reducing cost of surface finish reducing
the cost of extra procedures such as polishing and chemical finishing by creating
the perfect blend between three parameter of CNC milling namely feed rate, depth
of cut and rpm to ensure a surface finish having value of 0.5 microns is achieved.
TERMINOLOGIES
Spindle
The spindle is present in interior of headstock and is driven with a belt
running from the motor pulley to a pulley on the back end of the spindle shaft.
The nose of the spindle is treaded on the outside to encounter chucks and tapered
on the inside to receive other accouterments.
Headstock
Fatigue
It is the weakening of material or structural damage which occurs by
repeatedly applied loads.
Corrosion
It is the chemical reaction particularly oxidation of metal to convert it into
more stable form such as it oxides. It is natural process.
Arbor
It is a mechanical component on which is used as prolongation part of the
spindle in horizontal milling machine. It is accommodated on the spindle if
required. It holds the tool and moves it in accurate direction.
Hardness
It is the measure of resistance of material to permanent change whenever
force is applied.
Chips Formation
Whenever machining operation is done on material the material is removed in
form of chips.
Work piece
It is the part or piece of material on which machining process are accomplished.
Surface finish:
It is the deviation of a surface from a flat ideal plane and is a measurement of how
smooth a surface can be.
Surface roughness:
Surface roughness often shortened to roughness, is a component of surface
texture. It is quantified by the deviations in the direction of the normal vector of a
real surface from its ideal form. If these deviations are large, the surface is rough;
if they are small, the surface is smooth.
Lay:
Lay is the direction of the predominant surface pattern ordinarily determined by
the production method used. Lay can be defined by various patterns such as
vertical, horizontal, radial, cross hatched circular, isentropic and others.
Waviness:
Waviness is the measure of surface irregularities with a spacing greater
than that of surface roughness. These usually occur due to warping, vibrations, or
deflection during machining.
Engineering Tolerances:
Engineering tolerance is the permissible limit or limits of variation
in physical dimensions, properties, parameter (temperature, humidity).
LIST OF FIGURES
Introduction
1.1 Opening Statement:
Surface roughness is usually the irregularity in the
components of the metal surface. It depicts the state of the machined surface.
These irregularities are admissible up to very low tolerances. Achievement of a
smooth surface finish is an important measure for quality of a product and can
greatly reduce the wear and tear of different parts of the machinery as well as
optimizes the production cost. Many mechanical properties like fatigue behavior,
resistance to corrosion etc. and the functional attributes like friction, light
reflection, heat transfer and electrical conductivity and all these properties depend
on surface roughness. For decades studies have been done in optimization of
various controlling parameters to achieve maximum possible surface finish. One
of the renowned method is using the Response Surface Method (RSM).
2.4 Parameters
There are different parameters that effect the surface
finish of a product using milling. The following are the parameters effecting the
surface finish of milled product
2.4.1 Cutting Speed
The cutting speed is in meters per minute which the
circumference covers. The rpm of the spindle depends upon the size of the cutter.
The best speed is obtained according to the material being used and the size and
type of the cutter and also the fluid being used. The following are some factors
that determine the speed of the cutter
The cutters having positive rake cut easily than those without rake thus
can be operated with higher speeds.
Cutters having angles run slow than plain cutters.
Sharp cutters can cut more than blunt so can be operated at higher speeds
A large supply of cutting oil can enable the operator to operate at higher
speeds
The type of surface finish required
The rigidity of the machine and work setup
2.4.2 Feed
Feed is the speed at which the work piece passes the cutting tool and
it is used to know the time for the process. The following are the factors that can
determine the feed of the process accordingly
The feed depends upon the depth and the width of the cut.
The type of cutter being used
The sharpness of the cutter
The material of the workpiece
It also depends on the strength and uniformity of the workpiece
The type of finish required
The power and the rigidity of the machine, the device that is holding the
workpiece and the tooling setup
y = f (x) + E
In which according to our project
Y= Surface Roughness
X= Input parameters such as Cutting Speed, Feed and Depth of Cut
3.1 INTRODUCTION
It is important to improve the performance of the systems and to
increase the yield of the processes without increasing the cost. This is refer to as
optimization. There is a parameter change in the general practice of determining
the optimal operating conditions while keeping the others at a constant level. This
is called one-variable-at-a-time technique. The major disadvantage of this
technique is that it does not include interactive effects among the variables and,
eventually, it does not depict the complete effects of the parameters on the
process. Also it is very time taking process. In order to overcome this problem,
optimization studies can be carried out using Response Surface methodology
(RSM).
3.2 METHODOLOGY
Response Surface Methodology (RSM) is a set of
mathematical and statistical techniques for empirical model building. It is very
beneficial for developing, improving, and optimizing the processes in which a
response (output) is effected by several variables and the goal is to optimize that
response. An experiment is a series of tests, called runs, in which changes are
made in the input variables which in turn effect the output. RSM has important
application in the design, simulation and formulation of new products as well as
in the betterment of existing product design. It depicts the influence of
independent variables alone or in combination on the process. In addition to
analyzing the effects of independent variables this experimental methodology also
generates a mathematical model. The application of RSM is to give optimized
response by reducing the cost of expensive analysis and saving time and effort
also.
For example our research is based upon 3 parameters i.e. cutting speed, feed rate
and depth of cut. Than RSM design 20 number of runs as
23 +2(3)+ 6=20
For now just to see how Minitab works, select -1 to +1 (by default) range of every
factor and see how it generates combinations.
Below is step by step explanation.
1. First of all select stat option from top bar. There select DOE (design if
experiment) followed by Response Surface and click on create response
surface design. (fig 1)
2. Here select design type. As shown in figure below select central
composite design. Also select number of factors or variables (3 in current
scenario). (fig 2)
3. Then press Entre key and 20 combinations will be generated. (fig 3)
Figure 3.1 Step 1 in Minitab
The range of set parameters will be chosen by considering the previous work in
this field. The range varies from experiment to experiment. Following are the
samples of two projects mostly identical to this project having different ranges.
The maximum surface finish which was obtained in these experiments was 0.6
microns.
As our objective is to obtain 0.5 microns or under optimized conditions up to 0.3
microns. So we will set these research papers as reference and set our range of
selected parameters (feed rate, depth of cut and spindle speed) accordingly.
TOOLING
4.1 INTRODUCTION
Tooling which is also called as machine tooling is the process of
acquiring the manufacturing components and machines needed for production.
Cutting tool or cutter is any tool which is used to remove material from the work-
piece by means of shear deformation. Cutting can be accomplished by single-
point or multipoint tools.
Diamond
Diamond synthetic in natural form, is the hardest of materials, and finds limited
use for turning and milling operations, grinding wheels and grinding wheel
dressers. Diamond tools cannot be used on ferrous metals as they have high
affinity to carbon.
Cubic boron nitride or CBN
CBN is the 2nd hardest tool material after diamond. It has a compressive
strength of 700,000 psi (4,830 mega pascals), twice the thermal
conductivity of copper. It is thermally stable and resistant to oxidation up to
3,500 F (1,925 C). Cubic boron nitride is used to machine both ferrous
and nonferrous metals that cannot be readily cut by other materials.
Flank wear in which the portion of the tool in contact with the finished
part erodes. Can be described using the Tool Life Expectancy equation.
Crater wear in which contact with chips erodes the rake face. This is
somewhat normal for tool wear, and does not seriously degrade the use of
a tool until it becomes serious enough to cause a cutting edge failure.
On the basis of weighting and rating matrix the diamond cutter has the largest
value as compared to Cubic Boron Nitride. So, we will use the diamond cutter.
Chapter 5
WORK PIECE
A work-piece is a piece of raw material that is in the process of being formed into
a component or part.
5.1 WORKPIECE MATERIAL GROUPS
In metal cutting industry, wide variety of components are machined from many
different materials. Each material has its own unique characteristics and properties
that are influenced by the alloying elements, heat treatment, hardness, etc. These
combine to powerfully influence the choice of cutting tool geometry, grad and
cutting data.
Thus, work piece materials have been split up into VI major groups, in accordance
with the ISO-standard, and each group bears unique properties as far as
machinability is concerned.
ISO P: Steel is the largest material group in the metallic cutting off expanse,
cropping from unalloyed to high-alloyed material, including steel castings and
ferritic and martensitic stainless steels. The machinability is normally good,
but it differs a lot depending on material hardness, carbon content, etc.
ISO M: Stainless steels are materials alloyed with a minimum of 12% chromium.
Other alloys may include nickel and molybdenum. Dissimilar conditions, such as
ferritic, martensitic, austenitic and austenitic-ferritic (duplex), produce a large
class. Similarity amidst all these types is that the cutting borders are disclosed to a
great deal of heat, notch wear and built-up edge.
ISO K: Cast iron is, contrary to steel, a short-chipping type of material. Grey cast
irons (GCI) and malleable cast irons (MCI) are quite easy to machine. On the
other hand nodular cast irons (NCI), compact cast irons (CGI) and austempered
cast irons (ADI) are more difficult. All cast irons comprise SiC, which is very
abrasive to the cutting edge.
ISO N: Non-ferrous metals are softer metals, such as aluminum, copper, brass etc.
Aluminum with a Si-content of around 13% is very abrasive. Normally high
cutting speeds and durable tool lifespan can be expected for inserts with sharp
edges.
ISO H This group includes steels with a hardness between 45-65 HRc, and also
chilled cast iron around 400-600 HB. The hardness makes them all difficult to
machine. The materials generate heat during cutting and are very abrasive for the
cutting edge.
1000 series are chiefly pure aluminum with a minimal 99% aluminum
content by weight and can be work hardened. 2000 series are alloyed with
copper Cu, can be precipitation hardened to strengths comparable to steel.
Formerly referred to as duralumin. They were at one time the most common
aerospace alloys, but were susceptible to stress corrosion cracking3000 series
are alloyed with manganese Mn, and can be work hardened.
5000 series are alloyed with magnesium Mn. They offer excellent
corrosion resistance, making them suitable for marine applications.
6000 series are alloyed with magnesium Mn and silicon Si. They are easy
to machine, are weldable, and can be precipitation hardened, but not to the
high strengths that 2000 and 7000 can reach. 6061 alloy is one of the most
commonly used alloy in daily life.
7000 series are alloyed with zinc, and can be precipitation hardened to the
highest strengths of any aluminium alloy (ultimate tensile strength = 700 MPa
for the 7068 alloy).
8000 series are alloyed with other elements which are not covered by other
series. Examples are Aluminium-lithium alloys.
Pandalloy: Pratt and Whitney proprietary alloy. They have high strength
and superior high temperature performance.
Magnalium:
Chapter 6
6.1 FATIGUE
Fatigue strength is highly dependent on surface finish and is strongly
influenced by surface finish and surface treatment. Fatigue is a surface sensitive
process and the fatigue cracks develop from free surfaces having cyclic loading
processes. The fatigue life decreases as the surface roughness increases due to the
development of microcracks and microvoids. This may lead to material failure
and other undesirable outcomes.
6.3 FRICTION
Friction is the resistance produced when two surface come into contact
therefore surface roughness plays a very important part in the value of coefficient
of friction. The friction coefficient increases with increase in surface roughness.
This is very important in many industries such that of gear making to ensure the
right amount of friction can be given to the gear as to avoid slipping as well as
stagnation.
6.4 LIGHT REFLECTION
The surface roughness has a large effect on the reflective properties of a material.
The reflectiveness of the material is termed as gloss and has a linear relationship
with surface roughness meaning lower the gloss higher the surface roughness and
lower the surface reflectance. This results in a surface that scatters or absorbs
much of the light that falls on the object.
A project risk assessment was conducted to identify the factors that might result in
the delay or failure in completion of the project.
The process of risk assessment was carried out in three phases which are as under.
Risk Identification
Risk Assessment
Risk Management
The intensity of likelihood and impact are rated based on following grade as
under.
1 = Low
2 = Medium
3 = high
Risk
Descripti Consequ Likelihoo Risk
Risk Impact Manage
on ences d Rating
ment
Can result in Proper
Dangers of hot
1 Safety a burning 1 1 2 safety
chips burning skin
incident measures.
The cost of the Suitable
project exceeds the substitutes
2. Cost Financial loss. 1 2 2
amount specified in will be
the SOR. arranged.
Experimental Materials will
The quality of the results will be properly
Material
3. materials used is not match 2 3 6 checked
Quality
poor. theoretical before
values selection.
Tool will be
Poor Quality tool is Inaccurate purchased
4. Tool Quality 2 3 6
used results from reliable
sources
Increase
Human error causes number of
Inaccurate
Performanc measurement that experiments
4. experimental 1 3 3
e are not up to the and take
results.
mark average
value
Items will be
The items to be Fabrication of
purchased
Availability purchased are short the project
5. 1 3 3 as soon as
of items or are unavailable will be
possible if
in the country. delayed.
required
The risk rating of each factor was evaluated using the following relation.
Risk rating = Likelihood x Impact
1 Introduction
1.1 Preamble
1.1.1 Variability of CNC parameters, converging to the
point of creating a relationship between speed,
RPM, feed rate and depth of cut to improve surface
finish of aluminum to close tolerances.
1.2 Scope
1.3.1 Books
1.3.2 Software
SolidCAM
Creo 2.0
http://dx.doi.org/10.1155/2016/4680380
1.4 Symbols
1.5 Deliverables
2 Technical Requirements
Cost of materials
3 Hazards/Safety
Project Advisor's
Signature