scholarly journals Effect of feed rate and depth of cut on face milling process on surface roughness of Al-Mg alloy using CNC milling machine 3 axis

2021 ◽  
Vol 3 (11) ◽  
pp. 11-18
Author(s):  
Rachmawati Achadiah ◽  
Putu Hadi Setyarini ◽  
Mas Ayu Pambayoen ◽  
Irfan H. Djunaidi ◽  
Dan Sti Azizah
Keyword(s):  
Surface Roughness ◽  
Control System ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Rate Variation ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

The purpose of this study was to determine the effect of feed rate and depth of cut on the surface roughness of Al-Mg aluminum using a DIY CNC Milling Machine and Krisbow Universal Milling Machine as a comparison. The open-loop control system is a control system used in the design of DIY CNC Milling machines. A PC with Mach3 software is used as a PC Based Direct Digital Controller to control the system. In this study, the feed rate variation 24 mm/minute and 42 mm/minute and depth of cut 0.25 mm, 0.5 mm, and 0.75 mm were used. After the face milling process, the surface roughness test was carried out using the Mitoyo Surface Roughness Tester to determine the level of surface roughness of the machining results the DIY Milling Machine and Krisbow Universal Milling Machine as a comparison. The results showed that as the feed rate and depth of cut increased, the surface roughness values of both tools increased.

scholarly journals Sustainable Manufacturing and Parametric Analysis of Mild Steel Grade 60 by Deploying CNC Milling Machine and Taguchi Method

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1303
Author(s):  
Shakir Azim ◽  
Sahar Noor ◽  
Qazi Salman Khalid ◽  
Aqib Mashood Khan ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Sustainable Manufacturing ◽  
Steel Grade ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant.

scholarly journals OPTIMASI PARAMETER PERMESINAN TERHADAP WAKTU PROSES PADA PEMROGRAMAN CNC MILLING DENGAN BERBASIS CAD/CAM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
I G.N.K. Yudhyadi ◽  
Tri Rachmanto ◽  
Adnan Dedy Ramadan
Keyword(s):  
Cutting Speed ◽  
Operation Time ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Machining Parameter

Milling process is one of many machining processes for manufacturing component. The length of time in the process of milling machining is influenced by selection and design of machining parameters including cutting speed, feedrate and depth of cut. The purpose of this study to know the influence of cutting speed, feedrate and depth of cut as independent variables versus operation time at CNC milling process as dependent variables. Each independent variable consists of three level of factors; low, medium and high.Time machining process is measured from operation time simulation program, feed cut length and rapid traverse length. The results of statistically from software simulation MasterCam X Milling, then do comparison to CNC Milling machine.  The data from experiments was statistical analyzed by Anova and Regression methods by software minitab 16.Results show that the greater feedrate and depth of cut shorten the operation time of machinery, whereas cutting speed is not significant influence. Depth of cut has the most highly contribution with the value of 49.56%, followed by feedrate 43% and cutting speed 0.92%. Optimal time of machining process total is 71.92 minutes, with machining parameter on the condition cutting speed is 75360 mm/minutes, feedrate is 800 mm/minutes and depth of cut = 1 mm. Results of comparison time machining process in software Mastercam X milling with CNC Milling machine indicates there is difference not significant with the value of 0,35%.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Optimizing the Machining Parameters in Glass Grinding Operation on the CNC Milling Machine for Best Surface Roughness

2010 ◽  
Vol 154-155 ◽  
pp. 721-726 ◽  
Author(s):  
Mohd Sayuti ◽  
Ahmed Aly Diaa Mohammed Sarhan ◽  
Mohd Hamdi Bin Abd Shukor
Keyword(s):  
Surface Roughness ◽  
Machining Process ◽  
Depth Of Cut ◽  
Response Analysis ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Tool Diameter

Glass is one of the most difficult materials to be machined due to its brittle nature and unique structure such that the fracture is often occurred during machining and the surface finish produced is often poor. CNC milling machine is possible to be used with several parameters making the machining process on the glass special compared to other machining process. However, the application of grinding process on the CNC milling machine would be an ideal solution in generating special products with good surface roughness. This paper studies how to optimize the different machining parameters in glass grinding operation on CNC machine seeking for best surface roughness. These parameters include the spindle speed, feed rate, depth of cut, lubrication mode, tool type, tool diameter and tool wear. To optimize these machining parameters in which the most significant parameters affecting the surface roughness can be identified, Taguchi optimization method is used with the orthogonal array of L8(26). However, to obtain the most optimum parameters for best surface roughness, the signal to noise (S/N) response analysis and Pareto analysis of variance (ANOVA) methods are implemented. Finally, the confirmation test is carried out to investigate the improvement of the optimization. The results showed an improvement of 8.91 % in the measured surface roughness.

Evaluation of Face Milling Operation Parameters on Surface Roughness of Crankcase Housing by Two Level Factorial Design with Center Points

2018 ◽  
Vol 780 ◽  
pp. 105-110
Author(s):  
Ukrit Thanasuptawee ◽  
Chamrat Thakhamwang ◽  
Somsak Siwadamrongpong
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Significance Level ◽  
Machining Center ◽  
Semi Solid

In this study, there are three machining parameters consist of spindle speed, feed rate and depth of cut which were conducted through full factorial with four center points to determine the effect of machining parameters on the surface roughness and verify whether there is curvature in the model for CNC face milling process in an automotive components manufacturer in Thailand. The workpieces used semi-solid die casted ADC12 aluminum alloy crankcase housing which they were performed by the ARES SEIKI model R5630 3-axis CNC vertical machining center and face milling cutter with diameter of 63 millimeters. The surface roughness of face-milled was measured by the surface roughness tester. It was found that the greatest main effect influence to surface roughness was spindle speed, followed by feed rate and depth of cut at significance level of 0.05.

An Investigation of Optimum Cutting Conditions in Face Milling Semi-Solid Cast 6061 Aluminum Alloy Using Carbide Tool

2013 ◽  
Vol 747 ◽  
pp. 777-780 ◽  
Author(s):  
S. Rawangwong ◽  
Worapong Boonchouytan ◽  
J. Chatthong ◽  
R. Burapa
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Face Milling ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Optimum Cutting ◽  
The Mean ◽  
Main Factors ◽  
Semi Solid

The purpose of this research was to investigate the effect of the main factors of the surface roughness in semi-solid 6061 aluminum face milling. This study was conducted by using computer numerical controlled milling machine. The controlled factors were the speed, the feed rate and the depth of cut which the depth of cut was not over 1 mm. For this experiment, we used factorial designs and the result showed that the factors effected of surface roughness was the feed rate and the speed while the depth of cut did not effect with the surface roughness. Furthermore, the surface roughness was likely to reduce when the speed was 4,200 rpm and the feed rates was 1,300 mm/min. The result of the research led to the linear equation measurement value which was Ra = 0.186 - 0.000034 Speed + 0.000047 Feed rate. The equation formula should be used with the speed in the range of 3,200-4,200 rpm, feed rate in the range of 1,300-1,800 mm/min and the depth of cut not over 1 mm. The equation was used to confirm the research results, it was found that the mean absolute percentage error of the surface roughness obtained from the predictive comparing to the value of the experiment was 4.12%, which was less than the specified error and it was acceptable.

scholarly journals The Utilizing Cutting Fluid And Feeding Rate Effect To The Surface Hardness And Precission Of Aluminum Material Using Cnc Milling Machine

2017 ◽  
Vol 16 (1) ◽  
Author(s):  
Widhaya Bastian Purnama ◽  
Indri Yaningsih ◽  
Heru Sukanto
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Surface Hardness ◽  
Cutting Fluid ◽  
Rate Variation ◽  
Milling Machine ◽  
Cnc Milling ◽  
Affecting Factors ◽  
Cnc Machine ◽  
Precision Rate

There are many factor affecting the quality of product that are produced from milling machine process. The quality is mostly about surface roughness and precision. Those affecting factors are the selection of cutting parameter and use of cutting fluid. The research is done in order to know the effect of using cutting fluid and feed rate to aluminum on surface roughness and precision using Milling CNC machine. This research uses milling CNC Mitsubishi M70 machine. The free variables of feed rate are 20, 32, 45, 69, 108 mm/min. Each feed rate variations are given cutting fluid and no- cutting fluid treatment. The cutting fluid used is bromus oil which is mixed with water. The tests performed were surface roughness test, precision test. The result of this study shows that feed rate is in line with surface roughness. The use of cutting fluid affects surface roughness. The surface roughness score at feed rate variation using coolant treatment are 20, 32, 45, 69, 108 mm/min shows the surface roughness score of 0,442; 0,484; 0,553; 0,643; 0,797 μm. surface roughness score without cutting fluid treatment reveals the score of 0,470; 0,517; 0,582; 0;662; 0,847 μm. According to statistical analysis result using two way ANOVA, it can be concluded that the use of cutting fluid and feed rate affect precision at 95% trust rate. The measurement of A dimension using cutting fluid in the variation of feed rate 20, 32, 45, 69, 108 mm/min shows the precision rate of 99,999348; 99,99929; 99,999304; 99,999261; 99,9992 %. While, the variation without cutting fluid treatment reveals the precision rate at 99,999188 ; 99,999184; 99,999037; 99;998884; 99,998684 %.

Application of Taguchi and Response Surface Methodologies for Surface Roughness in Rotary Tool Polishing Hardness Mould Steels

2011 ◽  
Vol 87 ◽  
pp. 82-89
Author(s):  
Potejanasak Potejana ◽  
Chakthong Thongchattu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Laser Scanning ◽  
Cutting Speed ◽  
Optimal Level ◽  
Confocal Laser ◽  
Milling Machine ◽  
Cnc Milling ◽  
Polishing Process ◽  
Cnc Milling Machine

This research proposes a new application of 3-axis CNC milling machine for polishing the 60 HRC hardness steels. The rotary polishing tools are designed by refer to the end-mill ball nose’s design. The diamond powder are coated in rotary polishing tools by resinoid bonding method and concentrated in 4.4 karat/cm2. The Zig-milling tool paths are used to polish the hardness steel. After polishing, the confocal laser scanning microscope is used to analyze the arithmetic mean surface roughness of the hardness steels. The L12 orthogonal array of the Taguchi’s method is selected to conduct the matrix experiment to determine the optimal polishing process parameters. The diamond grit size and cutting speed of the rotary polishing tools, feed rate and step over of the tool path, the depth of polishing process penetration, and polishing time are used to study. The combination of the optimal level for each factor of the hardness steel polishing process are used to study again in the confirmation experiment. The predicted signal to noise ratio of smaller - the better under optimal condition are calculated by using the data from the experiment. The combination of the optimal level for each factor are used to study again in the confirmation experiment and the result show that polishing time was a dominant parameter for the surface roughness and the next was depth of penetration. The response surface design is then used to build the relationship between the input parameters and output responses. The experimental results show that the integrated approach does indeed find the optimal parameters that result in very good output responses in the rotary polishing tools polished hardness mould steel using CNC milling machine. The mean surface roughness of hardness steel polishing process is improved by the diamond rotary tools with the 3-axis CNC milling machine.

The Research of Linear Rotation-Axis Control Machining CNC Rotary Cam Surface Transformation

2012 ◽  
Vol 163 ◽  
pp. 138-142
Author(s):  
Feng Qin Ding ◽  
Yi Yu ◽  
Zhi Yi Miao
Keyword(s):  
Control System ◽  
Numerical Control ◽  
Data Conversion ◽  
Design Parameters ◽  
Milling Machine ◽  
Numerical Control System ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Straight Line ◽  
Linear Movement

General CNC milling machine for special transformation in the middle and low numerical control system of internal control software does not change under the premise of achieving the original system does not have the linear movement and rotary movement of the operating linkage function. The numerical control system of linear movement into rotary movement of the operation, and expansion of two straight line linkage CNC system functions, cleverly converted to a straight line movement control of a rotary movement of the linkage, thereby achieving the surface of the cylinder rotating cam track surface CNC machining. CNC Milling through the difficult parts of the application examples to explain the design principles of transformation CNC milling machine, design approach,As well as the design parameters in the programming of data conversion. And data conversion processing errors resulting from the measures and the elimination of error analysis.

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