Investigation of machining parameter for face milling operations on various materials Members:- P.Abupakkar sidhic, ( ) J.Kavirajan, ( ) S.Manikandan, ( ) R.H.Raaj Kumar. ( ) 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 milling Materials We are going to perform our task on the material Aluminium, Copper, Tool used High speed steel Carbide.

Parameters : Input i.Speed ii.Feed iii.Depth of cut Find out: i.Material Removal Rate ii.Machining Time iii.Machining Cost iv.Surface roughness

specification work piece : Shape - Cube size - 32x32x32 mm

Vertical milling machine

Machine specificationMode –super mini mill Travel: x-axis y axis z axis 406 mm 305mm 254mm Table dimension: length width 914mm 730mm Spindle : speed max.motor rating rpm 11.2kw Feed rates: maximum rapids max cutting 30.5m/min 21.2m/min Tool : capacity type max.tool diameter max. tool weight 10 CT40 89mm 6.4kg Accuracy : positioning repeatability +/ mm +/ mm Gentral:power15kw

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”.

WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase X X X X X X X X X X X X X X X X X X X X X X X X X X X32

WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase λ= x x x x x x x x x x x x x x x x x x x x x x x x x x

WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase X X X X X X X X X X X X X X X X X X X X X X X X X X X33

WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase x x x x x x x x x x x x x x x x x x x x x x x x x x x33

Formulae MATERIAL REMOVAL RATE, MRR = f*w*d.o.c (mm 3 /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 at constant d.o.c

aluminum in carbide tool at constant speed

aluminum in carbide tool

aluminum in hss tool at constant d.o.c

aluminum in hss tool at constant speed

aluminum in hss tool

Copper in carbide 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