EXPERIMENTAL INVESTIGATION OF THE MINIMUM QUANTITY LUBRICATION IN END-MILLING OF AA6061T6 BY COATED CARBIDE TOOLS ABDUL MUHAIMIN BIN ARIS Report submitted in partial fulfillment of requirements for award of the Degree of Bachelor of Mechanical Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG JUNE 2013
UNIVERSITI MALAYSIA PAHANG JUDUL: BORANG PENGESAHAN STATUS TESIS EXPERIMENTAL INVESTIGATION OF THE MINIMUM QUANTITY LUBRICATION IN END-MILLING OF AA6061T6 BY COATED CARBIDE TOOLS SESI PENGAJIAN: 2012/2013 Saya ABDUL MUHAIMIN B ARIS (900409-03-5131) (HURUF BESAR) mengaku membenarkan tesis (Sarjana Muda/Sarjana /Doktor Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: KUARTERS FELDA WILAYAH MEMPAGA DR. MD. MUSTAFIZUR RAHMAN PEJABAT FELDA WILAYAH MEMPAGA ( Nama Penyelia ) 28600,KARAK PAHANG DARUL MAKMUR Tarikh: 24 JUNE 2013 Tarikh: : 24 JUNE 2013 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
ii EXAMINER S DECLARATION I certify that the project entitled Experimental Investigation of The Minimum Quantity Lubrication in End-Milling of AA6061-T6 by Coated Carbide Tools is written by Abdul Muhaimin bin Aris. I have examined the final copy of this report and in my opinion, it is fully adequate in terms of language standard, and report formatting requirement for the award of the degree of Bachelor Engineering. I herewith recommend that it be accepted in partial fulfilment of the requirements for the degree of Bachelor Mechanical Engineering. (Saiful Anwar Bin Che Ghani) Examiner Signature
iii SUPERVISOR S DECLARATION I hereby declare that I have checked this thesis and in my opinion, this report is satisfactory in terms of scope and quality for the award of the degree of Bachelor of Engineering (Mechanical). Signature :. Name of Supervisor : DR. MD. MUSTAFIZUR RAHMAN Position : ASSOCIATE PROFESSOR Date : 24 JUNE 2013
iv STUDENT S DECLARATION I hereby declare that the work in this project is my own except for quotations and summaries which have been duly acknowledged. The report has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature :.. Name : ABDUL MUHAIMIN BIN ARIS ID Number : MA09076 Date : 24 JUNE 2013
ix TABLE OF CONTENTS EXAMINER S DECLARATION SUPERVISOR S DECLARATION STUDENT S DECLARATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF ABBREVIATIONS Page ii iii v vi vii viii ix xii xiii xv xvi CHAPTER 1 INTRODUCTION 1.1 Introduction 1 1.2 Problem Statement 2 1.3 Objectives of the project 3 1.4 Project scope 3 1.5 Organization of the project 4 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 5 2.2 Milling Machine 5 2.2.1 Type of Milling Machine 6 2.2.2 End Milling Machine 8 2.2.3 Operation of Milling Machine 9 2.3 Coated Carbide Tools 9 2.4 Minimum Quantity Lubrication 10 2.5 Aluminum Alloy 11
x 2.6 Process Parameters 11 2.6.1 Cutting Speed 12 2.6.2 Feed Rate 13 2.6.3 Axial Depth of Cut 14 2.7 Response Parameters 15 2.7.1 Tool Wear 15 2.7.2 Surface Roughness 17 2.7.3 Material Removal Rate 18 2.8 Summary 18 CHAPTER 3 METHODOLOGY 3.1 Introduction 19 3.2 Materials Properties 20 3.3 Cutting tool 22 3.4 Machining Parameters 23 3.4.1 Input Parameters 24 3.4.2 Output Parameters 25 3.5 Experiment Set Up 29 3.6 Data Collection 31 3.7 Summary 32 CHAPTER 4 RESULTS AND DISCUSSION 4.1 Introduction 33 4.2 Machining Parameters and Design of Experiments 33 4.3 Surface Roughness 34 4.3.1 Mathematical modelling 34 4.4 Material Removal Rate 42 4.4.1 Mathematical modelling 42 4.5 Tool Wear 47 4.5.1 Mathematical modelling 47 4.6 Optimization Value 53 4.7 Summary 54
xi CHAPTER 5 CONCLUSION AND RECOMMENDATIONS 5.1 Introduction 55 5.2 Conclusion 55 5.3 Recommendations 56 REFERENCES 57
xii LIST OF TABLES Table No. Title Page 3.1 Chemical composition of the aluminum alloy 6061-T6 21 3.2 Composition of the coated carbide inserts 22 3.3 Parameters for MQL Machining. 23 3.4 Input and output parameters 24 3.5 The specification for CNC milling machine HAAS VF-6 30 4.1 Design of Experiment Matrix for MQL 34 4.2 Design of Experiment Matrix for flooded 34 4.3 Variance analysis for the second order model of the surface roughness MQL and flooded 4.4 Experimental and predicted results second order model RSM of surface roughness for MQL 4.5 Experimental and predicted results second order model RSM of surface roughness for flooded 36 37 38 4.6 Variance analysis for second orders MRR for MQL and flooded 43 4.7 Experimental results RSM second order material removal rate predicted values for flooded 4.8 Experimental results RSM second order material removal rate predicted values for MQL 45 46 4.9 Variance analysis for second orders tool wear for MQL and flooded 48 4.10 Experimental and predicted results second order model RSM of tool wear for flooded 4.11 Experimental and predicted results second order model RSM of tool wear for MQL 49 51 4.12 The optimization of MQL and flooded for coated carbide inserts 53
xiii LIST OF FIGURES Figure No. Title Page 2.1 Vertical milling machine 7 2.2 Horizontal milling machine 7 2.3 End milling process 8 2.4 Different operation of miling machine 9 2.5 End milling (Milling machine) operation. 15 2.6 The comparison of the tool wear for different cutting processes 16 3.1 Flow chart of the study 20 3.2 Workpiece block. 21 3.3 Tool holder and cutting tool insert and insert coated carbide tool 25 3.4 Graph position for average roughness (Ra) 26 3.5 Tool wear depend on the technique use. 26 3.6 The movement of tool in horizontal milling machine. 28 3.7 The movement of tool in vertical milling machine. 29 3.8 CNC milling machine HAAS VF-6 29 3.9 Portable roughness tester model MarSurf PS1 31 3.10 Optical video measuring system 32 4.1 Image of surface roughness for maximum cutting speed MQL and flooded 38 4.2 Image of surface roughness for maximum feed rate MQL and flooded 39 4.3 Image of surface roughness for maximum depth of cut MQL and flooded 39 4.4 Surface roughness versus MQL 40 4.5 Surface roughness versus feed rate using (a) MQL (b) flooded 41
xiv 4.6 Surface roughness versus depth of cut for (a) MQL (b) flooded 41 4.7 Surface roughness versus cutting speed for (a) MQL (b) flooded 42 4.8 MRR versus depth of cut for (a) MQL (b) flooded 44 4.9 MRR versus feed rate for (a) MQL (b) flooded 46 4.10 MRR versus cutting speed for MQL (b) flooded 47 4.11 Image of tool wear (a) MQL (b) flooded 50 4.12 Tool wear versus MQL flow rate 50 4.13 Tool wear versus feed rate for (a) MQL (b) flooded 52 4.14 Tool wear versus depth of cut for (a) MQL (b) flooded 52 4.15 Tool wear versus cutting speed for (a) MQL (b) flooded 53
xv LIST OF SYMBOLS RPM v c f r f t n R a L Y V T C N W t L f m D Revolution per minute cutting speed feed rate in mm/rev Feed rate in mm/tooth Number of the teeth of cutter Average surface roughness Sampling length Ordinate of the profile curve Cutting speed Tool life (minutes) Taylor s constant for the unaccounted variables RPM of Cutter Width of cut (may be full cutter or partial cutter) Depth of cut Length of pass or cut Table (machine) Feed Cutter Diameter in mm
xvi LIST OF ABBREVIATIONS MQL RSM CNC TiC TiCN TiN PVD CVD NDM DOE RPM CBN GF ISO HSS CLA AA Ra MRR C S SR Minimum quantity lubrication Response surface method Computer numerical control Titanium carbide Titanium carbon nitride Titanium nitride Physical vapour deposition Chemical vapor deposition Near dry machining Design of Experiment Revolution per minute Cubic boron nitride Green factor International standard organization High Speed Steel Center Line Average Arithmetic Average Average roughness Material Removal Rate Cutting speed Surface roughness