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
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