UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PARAMETER SELECTION FOR MACHINING VARIOUS

TYPE OF MATERIAL IN MILLING MACHINE

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor of Manufacturing Engineering

Technology (Product Design) with Honours

by

SURAYA BT SAAD

B071210413

880218-02-5410

FACULTY OF ENGINEERING TECHNOLOGY 2015

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: PARAMETER SELECTION FOR MACHINING VARIOUS TYPE OF

MATERIAL IN MILLING MACHINE

SESI PENGAJIAN: 2014/15 Semester 2

Saya SURAYA BT SAAD

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti

Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan

atau kepentingan Malaysia sebagaimana yang termaktub

dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

Kg Pida 14 Jln Sanglang,

06150 Ayer Hitam,

Kedah Darul Aman

Tarikh: ________________________

Disahkan oleh:

Cop Rasmi:

Tarikh: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT

atau TERHAD.

iv

DECLARATION

I hereby, declared this report entitled “Parameter Selection for Machining Various Type of Material in Milling Machine” is the results of my own research except as cited in references.

Signature :………………………

Name : SURAYA BINTI SAAD

Date : ………………………

v

APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Engineering

Technology (Product Design). The member of the supervisory is as follow:

……………………………….

(Project Supervisor)

vi

ABSTRACT

Surface finish is a surface texture also knows as characteristics of surface. The quality

of surface finish is very important because is able to effect the quality of product. Thus,

selection of correct machining parameters are able to produce high quality of surface

finish when machined workpiece. This project is to analysis the machining parameters

effect on surface roughness for different types of material for face-mill process in

milling operation. The machining parameters that will give effect on surface roughness

consist of cutting speed, feed rate, and depth of cut. The material used are mild steel

AISI 1018 and Aluminium 1100. Machining trial was conducted at different cutting

parameters using carbide cutting tool. After milling process, surface roughness value

was measure using the Mitutoyo Surface Roughness Tester SJ-410. The result of

surface roughness will be analysed using Variance of Analysis (ANOVA) software.

The main aim of this project is to determine the parameter that capable to produce

smooth and good surface finish with use computer numerical control (CNC) vertical

milling machine. Hopefully the result analysis can helpful student as reference during

operation the CNC milling machine at available in Manufacturing Technology

Engineering (FTK) Laboratory.

vii

ABSTRAK

Kekemasan permukaan ialah texture permukaan atau di kenali juga sebagai ciri-ciri

permukaan. Kualiti kemasan permukaan adalah sangat penting kerana ia akan

memberi kesan kepada kualiti produk yang dihasilkan. Oleh itu, pemilihan parameter

pemotongan yang sesuai mampu menghasilkan kualiti kekemasan pemukaan yang

baik pada bahan kerja yang dimesin. Projek ini adalah untuk menganalisis parameter

pemesinan yang memberi kesan kepada kekemasan permukaan untuk pelbagai jenis

bahan dengan mengunakan pengisaran muka dalam operasi pengisaran. Terdapat tiga

parameter pemesinan yang memberi kesan kepada kekasaran permukaan iaitu kelajuan

pemotongan, kadar suapan dan kedalaman pemotongan. Bahan yang digunakan dalam

projek ini adalah keluli lembut AISI 1018 dan aluminum 1100. Pemesinan akan

dilakukan pada parameter pemotongan yang berbeza menggunakan alat pemotong

karbida. Selepas operasi pengisaran dilakukan, nilai kekasaran akan diukur

menggunakan penguji kekasaran permukaan, SJ-410. Hasil kekasaran yang diperolehi

akan dianalisis mengunakan perisian analisis varian (ANOVA). Tujuan utama projek

ini adalah untuk menentukan parameter pemesinan yang mampu untuk menghasilkan

kekemasan permukaan yang lincin dan baik dengan mengunakan kawalan komputer

berangka (CNC) pengisaran. Semoga keputusan analisis ini dapat membantu pelajar

sebagai rujukan semasa mengunakan mesin pengisaran yang terdapat di makmal mesin

di Fakulti Teknologi Kejuruteraan Pembuatan.

viii

DEDICATIONS

I dedicate this report to my loving parents, Mr Saad bin Othman and Madam Kalsom

bt Kamis, whose words of encouragement and support towards my studies. I also

dedicate this research to my sibling for their support towards me since ever I was

further study. Without their support, I may not come out with a successful research.

May Allah always bless of them.

ix

ACKNOWLEDGMENTS

In the name of Allah, the most Gracious and most Compassionate

Praise to God for His help and guidance that I am able to complete the task of this

Bachelor Degree Project. A special thanks to my supervisor, Mr. Abd Khahar Bin

Nordin that had guided me throughout this study from the beginning until the end.

Besides, his had given me invaluable advices that empower my spirit and passion

toward the job and the tolerance of my silly mistakes. I would like to take this chance

to thank his for the support and encouragement whenever I faced any problems while

completing this study. I am very thankful for the time that his had been spent with me

for the study and correcting my mistakes even though his had a busy working schedule.

Many thanks to all of the technicians in Manufacturing Technology Laboratory,

Mr.Azimin, Mr. Hisyam and Mr. Fauzi for their cooperation and assisting me in the

various laboratory tasks. I would like to express thank to all of my friend because

helping directly or indirectly during the conducted my project. Without the help in

terms of ideas from them, it sure is hard for me to complete my project.

Deepest gratitude to my parents, who give me a support and care along completing my

study. Finally, I am grateful to University Technical Malaysia Melaka for all of support

during the period of this research work.

x

TABLE OF CONTENTS

DECLARATION ........................................................................................................ iv

APPROVAL ................................................................................................................. v

ABSTRACT ................................................................................................................ vi

ABSTRAK ................................................................................................................. vii

DEDICATIONS ........................................................................................................ viii

ACKNOWLEDGMENTS .......................................................................................... ix

TABLE OF CONTENTS ............................................................................................. x

LIST OF FIGURES .................................................................................................. xiv

LIST OF TABLE ....................................................................................................... xv

LIST OF SYMBOLS AND ABBREVIATIONS ..................................................... xvi

CHAPTER 1 ................................................................................................................ 1

1.0 Introduction ................................................................................................... 1

1.1 Background ................................................................................................... 1

1.2 Problem Statement ........................................................................................ 2

1.3 Project Objective ........................................................................................... 3

1.4 Scope of Study ............................................................................................... 3

1.5 Project Outline ............................................................................................... 4

1.6 Planning Project ............................................................................................ 5

CHAPTER 2 ................................................................................................................ 7

2.0 Introduction ................................................................................................... 7

xi

2.1 Milling Machine ............................................................................................ 8

2.2 Computer Numerical Control (CNC) Machines ........................................... 9

2.3 Milling Operation ........................................................................................ 12

2.3.1 Face milling .......................................................................................... 12

2.4 Milling Cutter and Insert ............................................................................. 15

2.5 Cutting Parameter ........................................................................................ 16

2.6 Workpiece Properties .................................................................................. 19

2.6.1 Aluminium ........................................................................................... 19

2.6.2 Mild Steel ............................................................................................. 20

2.7 Surface Roughness ...................................................................................... 20

2.7.1 Principal Elements of Surface .............................................................. 22

2.7.2 Surface Finish in Machining ................................................................ 23

2.8 Surface Roughness Tester ........................................................................... 23

2.9 Surface Roughness Parameter ..................................................................... 25

2.10 Analysis Of Variance (ANOVA) Software ................................................. 26

2.11 Chip Formation ............................................................................................ 28

CHAPTER 3 .............................................................................................................. 30

3.0 Introduction ................................................................................................. 30

3.1 Process Flow ................................................................................................ 30

3.2 Material Preparations .................................................................................. 31

3.3 Material Workpiece ..................................................................................... 32

3.3.1 Aluminum Alloy 1100 ......................................................................... 32

3.3.2 Mild Steel AISI 1018 ........................................................................... 33

xii

3.4 Parameter Selection ..................................................................................... 34

3.5 Method of Machining .................................................................................. 34

3.6 Apparatus ..................................................................................................... 35

3.7 Preparation machine .................................................................................... 36

3.8 Cutting Process ............................................................................................ 39

3.9 Labelling ...................................................................................................... 39

3.10 Surface Roughness Tester ........................................................................... 40

3.10.1 Surface Roughness Measurement ........................................................ 42

3.10.2 Surface Roughness Tester Calibration ................................................. 42

3.10.3 Taking Surface Roughness Measurement ............................................ 43

3.11 Data Analysis .............................................................................................. 43

CHAPTER 4 .............................................................................................................. 44

4.0 Introduction ................................................................................................. 44

4.1 Findings Average of surface roughness ...................................................... 45

4.2 Data analysis for mild steel specimen ......................................................... 47

4.2.1 Analysis of Interaction Plot for mild steel ........................................... 47

4.2.2 Analysis of Main Effect Plot for mild steel ......................................... 49

4.2.3 Analysis of Variance ............................................................................ 50

4.3 Data analysis for Aluminium specimen ...................................................... 51

4.3.1 Analysis of Interaction Plot .................................................................. 51

4.3.2 Analysis of Main Effect Plot for aluminium ........................................ 52

4.3.3 Analysis of Variance for aluminium .................................................... 54

4.4 Chip Formation ............................................................................................ 54

xiii

4.5 Factor that effect the result .......................................................................... 57

4.6 Limitation of research and future work suggestion ..................................... 59

CHAPTER 5 .............................................................................................................. 60

5.0 Introduction ................................................................................................. 60

5.1 Conclusion ................................................................................................... 60

5.2 Recommendation ......................................................................................... 61

REFERENCES ........................................................................................................... 66

xiv

LIST OF FIGURES

Figure 2.1: Type of milling machine ……………………………………………..... 9

Figure 2.2: Machine tool for CNC milling………………………………………….11

Figure 2.3.1 (a): Face Mill Operation……………………………………………….12

Figure 2.3.1 (b): Face Mill Operation, showing action of an insert………………....12

Figure 2.3.1 (c): Action of Climbing Milling………………………………………..13

Figure 2.3.1 (d): Action of Conventional Milling……………………………………13

Figure 2.3.1 (e): A face-milling cutter with index able insert……………………….14

Figure 2.4: Relative edge strength and tendency for chipping of insert with various shape. (The Goodheart-Willcox Co.)………………………………………………..15

Figure 2.7: Fishbone diagram with influential factors on machined surface roughness ……………………………………………………………………………………….20

Figure 2.7.1: Roughness and waviness profile............................................................21

Figure 2.8: Portable Surface Roughness SJ-410…………………………………….23

Figure 2.10(b): The interaction plot for surface roughness………………………….26

Figure 2.10(c): The main effects plot of surface roughness………………………....26

Figure 2.11: Types of chip formation………………………………………………28

Figure 3.1: Flow chart as a guild project……………………………………….........30

Figure 3.2: Material preparation for specimen………………………………………31

Figure 3.9: Labelling on specimen…………………………………………………...39 Figure 3.9: Surface roughness tester SJ-410………………………………………...39 Figure 4.2.1: Graph interaction plot for surface roughness……………………….....46

Figure 4.2.2: Graph main effect plot for surface roughness……………………….....48

Figure 4.3.1: Graph interaction plot for surface roughness…………………………..50

Figure 4.3.2: Graph main effect plot for surface roughness……………………….....51

Figure 4.4(a): Chip formation for mild steel specimen……………………………...54

Figure 4.4(b): Chip formation for aluminium specimen…………………………….55

xv

LIST OF TABLE

Table 1.6: Gantt chart for PSM 1…………………………………………………….5

Table 1.6: Gantt chart for PSM 2…………………………………………………….6

Table 2.5 (a): Cutting parameter in milling process……………………………........15

Table 2.5 (b): Cutting speed for different material…………………………………..17

Table 2.5 (c): Recommendation of cutting speed and feed rate……………………..17

Table 2.5 (d): Recomendation cutting parameters for aluminum…………………….18

Table 2.5 (e): Recomendation cutting parameters for plain carbon steel…………….18

Table 2.7.1: Definition of surface structure………………………………………….21

Table 2.10(a): Table of analysis of ANOVA………………………………………..25

Table 3.3.1 (a): Chemical composition of Aluminum 1100 alloy……………………31 Table 3.3.1 (b): Mechanical properties of Aluminum 1100 alloy……………………32 Table 3.3.2(a): Chemical composition of AISI 1018 carbon steel…………………..32 Table 3.3.2(b): Mechanical Properties of AISI 1018 carbon steel…………………...32 Table 3.4: Parameter selection for machining process……………………………….33 Table 3.6: Apparatus for machining process………………………………………..34

Table 3.9(a): Specification of SJ-401………………………………………………..40 Table 3.9(b): Features of SJ-410………………………………………………….....40 Table 4.1 (a): The overall data of average roughness value for mild steel…………..44

Table 4.1 (b): Detail result data for mild steel specimen……………………………..44

Table 4.1 (c): The overall data of average roughness value for Aluminium………….45

Table 4.1 (d): Detail result data for aluminium specimen……………………………45

Table 4.2: Result of average roughness value for mild steel………............................46

Table 4.2.3: ANOVA table for response function of the surface roughness………….49

Table 4.3: Result of average roughness value for aluminium………………………50

Table 4.3: Result of average roughness value for aluminium……………………….53

Table 5.2: Recommendation of ideal parameter……………………………………..60

xvi

LIST OF SYMBOLS AND ABBREVIATIONS

AA = Arithmetic Average

AL = Aluminium

ANOVA = Analysis of Variance

ANSI = American National Standard Institute

CLA = Center Line Average

CNC = Computer Numerical Control

Cu = Copper

DIN = German National Standard

F-test = Fisher Test

HSS = High Speed Steel

ISO = International Standard

JIS = Japanese Industrial Standards

mm = Millimetre

QC = Quality Control

Ra = Average Roughness

Rev/min = Revolution per Minute

Rp = Smoothing Depth

RPM = Millimeter per Revolution

Rq = Root mean square

SFM = Surface feet per minute

TiNC = Titanium Carbide

µm = Micrometre

1

CHAPTER 1 INTRODUCTION

1.0 Introduction

Surface finish is a surface texture also knows as characteristics of surface. The

quality of surface finish is very important because is able to effect the quality of

product. Thus, selection correct machining parameters are able to produce high quality

of surface finish when machined workpiece. Cutting parameters like cutting speed,

spindle speed, feed rate, and depth of cut is important in material remover. Surface

roughness influences some functions of work piece like contact causing surface

friction, fatigue resistance, wearing, heat transmission, and coating (Daud, Ng,

Sivakumar and Selamat, 2015). According to Suleiman, Usman and Apasi (2011),

cutting parameter selected based on the workpiece material, cutting tool material and

tool size will be used. This project is analysis the effect of cutting parameters like

cutting speed, feed rate, and depth of cut on surface roughness for different type of

material using CNC milling machine. This chapter will explain about project from

introduction, objectives, problems statement, project scope and project outline.

1.1 Background

The quality of the machined part are main challenges during milling machine.

Selection of cutting parameters is very important for type of material used because

their most significant effect on surface finish of workpiece. This research was made to

analysis the effect of cutting parameters like cutting speed, feed rate and depth of cut

on the surface finish. The machining and collecting data process was made in detail

using a CNC milling machine that is found in workshop manufacturing technology.

2

Two different type of material is used for doing this project, it is Aluminum 1100

alloy and Mild Steel AISI 1018. The flat shape of material is selected and machining

in form of flat surface. The cutter and the path of that cutter used to evacuate material

from the work piece is the face milling operation. The correct cutter material is very

important to tool life in order to avoid tool wear. Cutting tool material to machining

the remover surface is carbide insert. After milling process, surface roughness value

were measured using a portable surface roughness SJ-410. The result of surface

roughness were analyses using the Minitab software. Minitab software was performed

to identify the effect of cutting the effect of cutting parameters on surface finish.

This parameter will be studied and do the machining to produce data that can

used as references to new user that want to learn the milling process. These parameter

will used as guidelines to machinist in selecting the correct parameter of cutting tool

to the type of material being cut.

1.2 Problem Statement

Surface roughness and tolerances are most critical quality measures in product.

The quality of surface finish can affect the functionality of product, appearance and

reliability. Thus, the selection of correct cutting parameter is very important for

control the required surface quality. One of the ways to solve is problem is using a

correct cutting parameters for workpiece material. Therefore, it can improve the

quality surface roughness of the product. This project are study and analyses the

suitable cutting parameter for aluminum 1100 alloy and mild steel AISI 1018 in

milling operation.

3

1.3 Project Objective

The objective of this project are:

i. To study the effect of cutting parameter such as cutting speed, depth of cut and

feed rate on surface roughness for milling operation.

ii. To finding the correct cutting parameter to the type of material being cut.

iii. To analyses the result of cutting parameter for materials used.

iv. To produce sample, recommendation and references for new comes student in

machining technology (milling).

1.4 Scope of Study

To ensure that all project objectives are achieved, the following are few

important elements that must be followed. This project involved the experiment and

analysis. This experiment is conducted using a CNC milling machine (DMC 635 V

ecoline) vertical milling that available in laboratory manufacturing technology. For

machining process, the face milling operation and carbide insert as cutting tool are

used. The common material that available in the laboratory is mild steel and

aluminium, so the material was selected is aluminium 1100 alloy and mild steel AISI

1018 for do machining to determine the surface roughness. The variable cutting

parameter like cutting speed, feed rate and depth of cut is used to machining the

material, it is to determine the pattern that will be evaluated in order to select the

suitable cutting parameter to be used together with purpose to produce a smooth and

good surface finish. After finish the milling process, Surface Roughness Tester SJ-410

at the Metrology Lab is used to measure the value of surface roughness on the

workpiece.

4

1.5 Project Outline

The parameter selection for machining various type of material in milling

machine for PSM project is a combination of 5 chapters overall that contains and

explain the topics such as the introduction, literature review, methodology, result and

discussion, and lastly conclusion and recommendation.

Chapter 1: Introduction of the project. This chapter will concentrate about the project

and objectives of the project will be elaborated. It is followed by the explanation of

scope project, problem statements and project outline.

Chapter 2: This chapter will concentrate about the literature review. This chapter will

be explain with some of basic information about the milling machine and CNC milling

machine. Next, the surface roughness is reviewed together with milling cutting

parameter and cutting tool that play an important role in determining the surface

roughness material. Some literature reviews of current existing projects based on effect

of cutting parameter on surface finish are also be discussed.

Chapter 3: Methodology of the project. This chapter is consists of the procedure that

is used to conduct the whole research experiment from the beginning until the end of

project.

Chapter 4: Result and Discussion. The results obtained from this experiment will be

discussed. A graphs will be represent to shows the relationship between the parameters

and surface roughness it produced by different machining parameters like cutting

speed, feed rate and depth of cut. The factor that effect the result obtained will be

discussed.

Chapter 5: Conclusion and recommendation. In this chapter will concentrated on the

conclusions and further recommendations to improve this study in the future.

5

1.6 Planning Project

Table 1.6(a): Gantt chart for PSM 1

6

Table 1.6(b): Gantt chart for PSM 1

7

CHAPTER 2 LITERATURE REVIEW

2.0 Introduction

The demand for high quality and fully automated production focuses on the

surface condition of the product, primarily of the machined surface roughness, because

of its effect on appearance, product function, and reliability. For this reasons is

important to maintain consistent tolerances and surface finish. Preferable selections of

cutting parameters is important to produce components with good quality and high

tolerance. (Mohammed, Montasser, and Joachim, 2007). Biswajit, Susmita, Rai and

Saha (2014) state the surface roughness depends on few factors such as the geometry

of the cutting tool, tool material, work piece material, machine tool rigidity and few

cutting requirement such as cutting speed, feed rate and depth of cut. Several factors

such as wear of the cutting tool, chip formations and properties of the cutting tool, and

work piece material are uncontrollable parameter in real machining. According to

Kadirgama, Noor, Rahman, Rejab, Haron and Hossein (2009), surface finish can be

characterized by several parameters such as average roughness (Ra), maximum peak-

to-valley height (Rt), root mean square (Rq), and smoothing depth (Rp) that when the

cutting speed is added, productivity can be maximized, meanwhile, surface quality can

be improved. The Minitab Software is technique be used to show the relationship of

cutting parameter with the surface roughness measurement.

8

2.1 Milling Machine

Milling machine is most versatile and useful machine tools because they are

able performing a variety type of cutting operations. First milling machines was built

in 1820 by Eli Whitney (1765 to 1825). Now, many selection of milling machines with

various features are available. Kalpakjian and Schmid (2010) state the numerous

machines and operations are now being with computer control and machining centre.

But, manually controlled machines it is still widely used, particularly for small

production run because it’s cheap.

According to Joshua, David and Ismail (2015) milling is one of the common

removing processes or metal cutting. It is a process that of generating machined

surfaces with progressively removing a predetermined total of material or stock from

the work piece at a relatively slow rate of movement or feed with a milling cutter

rotating at a rather high speed. One other word, Bawa (2004) state the milling is a

material remover process, that is used for machining curve, flat, and irregular surfaces

by feeding the work piece against a rotating cutter that contain several cutting edges.

Axis of rotation the cutting tool perpendicular to the direction of feed, whether

perpendicular or parallel to machined surface. There are various types of milling

machines available in the market and has its own characteristics.

According to Kalpakjian and Schmid (2010), milling machine can be classified

based on their construction, specification and operation. Most of milling machines are

constructed of column and knee structure, it is used for General Purpose milling

operations with the spindle on which the milling cutter is mounted possible horizontal

for slab milling and vertical for face milling and end milling. Furthermore, fixed bed

type machines is the worktable is mounted directly on the bed that replaces the knee

and can moving only longitudinally. This machines is not versatile like other types,

but they have high stiffness and usually are used for high production work. The spindle

may be vertical duplex, horizontal, or triplex types with two or three spindle,

respectively for the simultaneous machining of two or three work piece surface. The

planer-type milling machines is similar with bed type machine, it also equipped with

cutters and few heads mill different surface. It is used for heavy work pieces and more

efficient than simple planer when used for similar purpose.

9

Now, various milling machine component are being replaced rapidly with

computer numerical control (CNC) machines. This machine are versatile and are

capable of milling, drilling and boring with repetitive accuracy. For this project, the

CNC vertical milling machine was used to machining the surface roughness.

Figure 2.1: Type of milling machine

2.2 Computer Numerical Control (CNC) Machines

Computer numerical control (CNC) milling machines also known as machining

centres. It was invented in the early 1970's. Before its invention, routing, drilling,

milling, and other types of machinery operated by numerical control (NC), that

required manual manipulation. According to Mwinuka, T.E., Mgwatu, M.I. (2015) the

CNC machine tool consists of three basic system that is part program, machine control