INVESTIGATION ON THE EFFECT OF CUTTING

PARAMETERS ON MACHINING OF ALUMINIUM USING

5-AXIS MACHINING

SHUKRI ZARIZI BIN KAMARUZAN

B050810126

UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2011

B050810126 BACH

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

INVESTIGATION ON THE EFFECT OF CUTTING

PARAMETERS ON MACHINING OF ALUMINIUM USING

5-AXIS MACHINING

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Process)

by

SHUKRI ZARIZI BIN KAMARUZAN

B050810126

FACULTY OF MANUFACTURING ENGINEERING

2011

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Investigation on the Effect of Cutting Parameters on Machining of Aluminium Using 5-Axis Machining

SESI PENGAJIAN: 2010/2011 Semester 1 Saya SHUKRI ZARIZI BIN KAMARUZAN 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 yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Disahkan oleh:

Cop Rasmi: Tarikh:

Alamat Tetap: No. 15 Kampung Parit Kudus,

82000 Pontian,

Johor Darul Ta’zim. 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.

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as

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

Manufacturing Engineering (Manufacturing Process) with Honours. The members

of the supervisory committee are as follow:

………………………………

Main Supervisor

(PROF. DR. MOHD RAZALI B. MUHAMMAD)

………………………………

Co-Supervisor

(DR. MD NIZAM B. ABD. RAHMAN)

DECLARATION

I hereby, declared this report entitled “Investigation on the Effect of Cutting

Parameters on Machining of Aluminium Using 5-Axis Machining” is the results of

my own research except as cited in references.

Signature : ……………………………....

Author’s Name : SHUKRI ZARIZI B. KAMARUZAN

Date :

i

ABSTRAK

Pengisar ialah bentuk paling biasa dalam memesin, proses pembuangan bahan ini

dilakukan bagi mewujudkan pelbagai bentuk dengan membuang jauh bahan yang

tidak dikehendaki. Sekarang ini, mesin CNC lima-paksi semakin meningkat naik

kerana boleh menyelesaikan sebuah bahagian yang kompleks. Oleh kerana itu,

projek ini akan memfokuskan kepada bahagian dinding atau sisi mata alat dengan

menggunakan mesin pengisar lima paksi. Membuat model (CAD) dan

pengaturcaraan (CAM) telah dibuat menggunakan perisian CATIA. Terdapat tiga

analisis utama akan dibawa keluar dan dianalisis. Iaitu kekasaran permukaan,

perubahan dimensi dan kehausan mata alat. Bahan mentah akan dipakai ialah

Aluminium dan menggunakan mesin DMU 60 MonoBlock. Dalam kekasaran

permukaan dan perubahan dimensi keadaan yang akan mempengaruhinya seperti

kadar kelajuan pusingan dan kadar suapan akan di analisis menggunakan kaedah

Rekabentuk Ujikaji (DOE) dengan cara Permukaan dengan Aturan (Response

Surface Methodology). Selain itu, kesan pada mata alat juga akan disiasat selepas

pemesinan dibuat. Dalam projek ini terdapat dua jenis alat pemotong akan digunakan

yang berbeza panjangnya. Penyebab kehausan mata alat seperti kadar kelajuan

pusingan dan kadar suapan setelah menjalankan proses pemesinan juga akan

dianalisa. Sementara itu, analisis akan dibuat menggunakan beberapa radas seperti

kekasaran permukaan penguji mudah alih (portable surface roughness tester), mesin

pengukuran koordinat (CMM), dan microskop optik (optical microscope).

Keputusannnya, kadar kelajuan pusingan dan kadar suapan telah member kesan

kepada permukaan kekasaran, ketetapan dimensi dan kehausan mata alat.

ii

ABSTRACT

Milling is the most common form of machining; a material removal process in which

can create a variety of features on a part by cutting away the unwanted material.

Nowadays, CNC machine of five axis machining become popular in order to solve a

complex machining of part. Hence, in this project will focus on flank milling using

five axis machining. The design modelling (CAD) and the machining programming

(CAM) have been developing using CATIA software. There were three main

analysis was carried out and analyzed. Namely the surface roughness, dimension

variation and tool wear. The raw material used is Aluminium and the machining

done using DMU 60 MonoBlock. In surface roughness and dimension variation the

influence happen will be analyze using Design of Experiment (DOE) method which

is Response Surface Methodology (RSM). Besides that, the effect happen in the tool

also has been investigated after the machining done. Meanwhile, the analysis was

successfully done using some apparatus such as portable surface roughness tester,

Coordinate Measuring Machine (CMM), and optical microscope. As the result, the

parameter such as spindle speed and feed rate is given influence to the surface

roughness, dimensional accuracy and tool wear.

iii

ACKNOWLEDGEMENT

First and foremost, praise to god that give me some health and ability to be here

preparing my Final Year Project with full of my intension of learning. With His

fortune and prosperity, I am finished project besides learning the experiences before I

am facing my reality of working life. I would like to express my deep and sincere

gratitude to my lecturer for the valuable guidance and advice; Prof. Dr. Mohd Razali

B. Muhammad, he has inspired me greatly to work in this project. Also not to forget

Dr. Md Nizam bin Abd. Rahman, my co-supervisor with his wide knowledge and

logical way of thinking has been beneficial for my. With this two person

understanding, encouraging and personal guidance have provided a good basis for

my project including completion of this PSM. Besides that, I would also like to thank

all of the people that involved both directly or indirectly helping me during the

project session and preparing this report successfully. These people are including

lecturer and staffs in UTeM, my fellow friends, partners and all people that

contribute in supporting me during this project from the beginning to the end of the

program. I would also like to thank the authority of UTeM for providing me with

good environment and facilities throughout the day of project. Finally, an honourable

mention goes to my family especially my beloved parents, with their understandings

and moral supports on me throughout the project and also in completing this report.

Without helps of the particular that mentioned above, I couldn’t complete the tasks

successfully. Thank you so much.

iv

DEDICATION

With honest, special thanks dedicated to my beloved parents, my PSM supervisor

and UTeM community, and my fellow friends and also to every single person who

has provide the opportunities with all your love, patience and understanding.

All your blessing will be granted

Thank You.

v

TABLE OF CONTENT

Abstrak i

Abstract ii

Acknowledgement iii

Dedication iv

Table of Content v

List of Tables viii

List of Figures ix

List Abbreviations xi

1. INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 3

1.3 Objective of Project 4

1.4 Scope of project 4

1.5 Structure of the Report 6

1.6 Activity Planning 7

1.7 Summary 7

2. LITERATURE REVIEW 8

2.1 The Milling Process 8

2.2 Milling of Aluminium 11

2.3 Surface Roughness 12

2.4 Cutting Tool and Tool Wear 15

2.5 Dimensional Variation 18

2.6 CAD/CAM 19

2.7 Design of Experiment (DOE) 20

2.8 Summary 21

3. METHODOLOGY 22

3.1 Introduction 22

vi

3.2 CAD/CAM 23

3.3 Squaring Process 29

3.4 Five Axis Milling Machine 29

3.5 Work piece Material 31

3.6 Tool Selection 31

3.7 Parameters for DOE 32

3.8 Analysis 34

3.8.1 Dimensional Variation 34

3.8.2 Surface Roughness 36

3.8.3 Tool Wear 37

3.9 Summary 38

4. RESULT 39

4.1 Introduction 39

4.2 Surface Roughness 40

4.3 Dimension Variation 41

4.4 Tool Wear Analysis 42

4.5 Design of Experiment (DOE) 46

4.5.1 Fit Summary 47

4.5.2 ANOVA 50

4.5.3 Interaction Plot 52

4.5.4 One Factor 53

4.5.5 Optimization 55

4.6 Summary 57

5. DISCUSSION 58

5.1 Introduction 58

5.2 Discussion 59

5.3 Summary 61

6. CONCLUSION 62

6.1 Conclusion 62

6.2 Future Works 63

vii

REFERENCES 64

APPENDICES

A Gantt Chart for PSM 1

B Gantt Chart for PSM 2

C Detail Drawing

D ISO for Surface Roughness

E Surface Roughness Result

F CMM Result

viii

LIST OF TABLES

2.1 Physical properties of aluminium alloy at room temperature

(Kalpakjian and Schmid, 2006) 11

3.1 Properties of aluminium alloy at room temperature

(Kalpakjian and Schmid, 2006) 31

3.2 Matrix of the RSM 33

3.3 Machining parameter 33

4.1 Data for surface roughness analysis 40

4.2 Show the measurement result get from CMM 41

4.3 Indicated the result of dimension variation and was calculate

using the percentage error 42

4.4 Images of the tool wears captured by optical microscope. 43

4.5 Overall data accumulated in Design Expert data sheet 46

4.6 The result of Fit Summary Analysis for surface roughness 48

4.7 The result of Fit Summary Analysis for dimension variation 49

4.8 The result of ANOVA for surface roughness 50

4.9 The result of ANOVA for dimension variation 51

4.10 Constraints and Solution for DOE 55

ix

LIST OF FIGURES

1.1 Project flow chart 5

2.1 Six kinds of configurations for five axis machine

(Lin and Koren, 2000). 9

2.2 Five axis milling operation (Baptista and Antune Simoes, 1999) 13

2.3 Roughness and waviness profile (Kalpakjian and Schmid, 2006) 13

2.4 Parameter affects surface roughness (Benardos and Vosniakos, 2003) 14

2.5 Tool with a severe built-up layer (Rivero et al. 2008) 17

2.6 The process of experiment (Paul and Robert, 2002) 20

3.1 Flow chart from CAD until NC code 23

3.2 Part or model selected in isometric views 24

3.3 Stock, plane, and machining reference were assembled together 25

3.4 Simulation of roughing process 26

3.5 Completed part and the simulation 27

3.6 The programming code (not fully) 28

3.7 The conventional milling machine 29

3.8 DMU 60 MonoBlock machine 30

3.9 Part name of the cutting tool 32

3.10 Wenzel Model LH54 35

3.11 Portable surface roughness testers 37

3.12 Optical microscope 38

4.1 Part and the line was investigate 39

4.2 Broken edges happen on the machining setup number 2nd (left)

and 10th (right) 45

4.3 Shows the interaction result between feed rate and surface roughness

to the surface roughness value 52

4.4 Shows the interaction result between feed rate and surface roughness

to the dimension variation value 53

x

4.5 One factor of spindle speed (left) and one factor of feed rate (right)

to Surface Roughness 54

4.6 One factor of spindle speed (left) and one factor of feed rate (right) to

Dimension 54

4.7 The graph was showed the relationship between feed rate and

spindle speed to the surface roughness 56

4.8 The graph was showed the relationship between feed rate and

spindle speed to the dimension variation 57

5.1 Feed rate part need to control 60

xi

LIST OF ABBREVIATIONS

Al - Aluminium

ANOVA - Analysis of Variance

CAD - Computer Aided Design

CAM - Computer Aided Manufacturing

CMM - Coordinate Measuring Machine

CNC - Computer Numeric Controlled

DOE - Design of Experiments

FWC - Floor-Wall and Ceiling

HSS - High speed steel

ISO - International Organization for Standardization

MM/MIN - Millimetre per Minute

NC - Numerical Control

PSM - Projek Sarjana Muda

R - Cylindrical cutter

Ra - Arithmetic average deviation

RPM - Revolutions per minute

Rq - Root-mean-square-roughness

RSM - Response Surface Methodology

V5 - Version 5

3D - Three-Dimensional

CHAPTER 1

INTRODUCTION

1.1 Background

Metal cutting is defined as the removal of metal chips from a work piece in order to

obtain a finished product with desired attributes of size, shape, and surface

roughness. Metal cutting process can be done by using several processes such as

machining, turning, grinding, threading and other. So this metal cutting is the most

significant in manufacturing processes. In machining contexts, the milling is some of

the processes used to remove material to produce a high quality of product.

Milling is typically used to produce parts that are not axially symmetric and have

many features, such as holes, slots, pockets, and even three dimensional surface

contours. Others application of milling is the fabrication of tooling for other

processes. An example of this is complex three-dimensional (3D) object such as

mould making and aircraft turbine making. In Computer Numeric Controlled (CNC),

milling is the one from several types of milling machine. This CNC machines now

have been used in our industries such as aerospace, automotive, fabrication,

instrumentation, machinery, and also mould and die making. Nowadays, this CNC

machine from 3-axis and have been improved to 5-axis. Thus, 5 axes milling

machine adding two more (A;B) axis in addition to the three normal axis (X;Y;Z).

The axis is determined by the modular or combination of axes in the respective

machine tools.

Milling is the indicated process when needed to make all the other part that cannot be

made on the lathe machining. The demand of low tolerances and better quality

product has forced in manufacturing industry to continuously progress in quality

control and machining technology. In 5-axis machining, there are two different

methods of tool approach. The first method is by using the face of the tool which

occurs in most machining processes and the second method is by using the body, side

or shaft of the cutting tool or also known as flank milling.

The 5-axis CNC milling machine is used for produce 3D contours. This machine

used typical program alphanumerical data coded. The data represent relative motion

position between cutting tool and a work piece. This machine actually flexibility to

manufacture a complex or impossible jobs. From this benefit, this machine become

widely use in the heavy industry and any application. The major components of this

machine are drive units, sliding system, and machine control unit.

This 5-axis milling machine can remove the material to produce a high quality

product. The important thing to produce the high quality product is the input

parameter and the output characteristics. The factors of input parameter that will

influence the final surface roughness; such as spindle speed, feed rate, and depth of

cut on control the cutting operation (Boothroyd and Knight, 1989). A product’s

quality is harder to attain and track than physical dimensions, because relatively

many factors affect product surface. Some of these factors can be controlled and

some could not.

Nowadays, in the industries, the dimension accuracy and the surface finish need

special attention to produce high quality product. In this project, it will investigate

about the surface roughness value and dimensional variation on flank cutting

condition. Most of the aerospace parts are thin and consist of pockets, flanges, and

arc shapes or contours. Flank milling or machining using the body of the tool is very

important and needs to focus and concentrate with full attention. After the

experiment was done, the effect of tool wear on the face and the body of the tool also

can be study. The contour that will be study is the curved shape profile.

1.2 Problem Statement

This 5-axis CNC machine is a new technology for our industries. In getting the high

of quality product from this machine is needed to studying about the surface

roughness of the product. Most of the works or research so far has focused on the

face milling. While the flank milling can provide large productivity gains for such

class of surfaces as are found in blades, fans, turbines and other engineering objects.

With flank milling the surface can be cut with a single pass, which is more efficient

than a point milling method. Thus, this project was initiated to investigate the flank

milling machining performance with certain sets of spindle speed, feed rate, and also

to investigate the effect on tool wear.

Considering the existing researches in flank milling, most of research spent more

attention on the tool path generation, positioning, and optimization of machining

accuracy. It is quite difficult to see a research in flank milling that concentrating on

the end result of the machining as what had been presented in this project such as

effect tool wear, surface roughness and dimensional accuracy. The number of

research found for analysis mentioned was done in five axis machining and were

used a different parameter setups.

The relationship between parameter and tool is very close, an example tool life

increase rapidly as the cutting speed increase. The tool life will be affected when the

cutting speed is slow. When the cutting speed is decreases, the force applied on the

product is high and the tool wear will effect quickly. Tool life is often involved with

the tool wear reaction that affects the product quality especially on the product

surface finish. Beside that there are more differences in tool life for different

material.

1.3 Objective of Project

The purposes of this project are:

a) To investigate the influence of spindle speed and feed rate on the surface

roughness value and dimensional variation to the flank cutting condition.

b) To study the effect of the tool wears on the face and body of the tool when

cutting is performed in flank milling for a curved shape profile.

c) Apply the Design of Experiment (DOE) method in terms of spindle speed and

feed rate.

1.4 Scope of project

Using the 5 axis CNC milling machine, this project will analyze the surface

roughness and dimensional variation of the curved shape part. During machining,

will use different value of spindle speed and feed rate. The project will use Design of

Experiment (DOE) method where the type of design is Response Surface

Methodology (RSM). Before the project started, parameter that wants to use will be

identified and the part modelling will be assisted as known as Computer Aided

Design (CAD) using CATIA software. Then the modelling will go through to

machining programming called Computer Aided Manufacturing (CAM) also using

the same software. Machining test for this project was carried out by using DMU 60

MonoBlock multi-axis CNC machine. The material used is Aluminium and the

cutting tool use has a 25mm cutting length. After done machining, the machined part

will be analysed about the surface roughness using portable surface roughness tester,

dimension variation using Coordinate Measuring Machine (CMM), and tool wear

using optical microscope. The result from this project will be record and analysed.

The flow chart of this project is at the Figure 1.1.

Figure 1.1: Project flow chart.

Define an objective of experiment

Part selection and Design of Experiment (DOE) application

Literature review and searching material

Modelling preparation using CATIA / CAMCAM

Running experiment using DOE set-up

Creating a programming with parameter according to DOE result

Start machining material

Analysis product: 1. Tool wear 2. Surface roughness 3. Dimension variation

Project Report

Tool path verification using

VERICUT software

Data collection and analysis using DOE

No

Yes

1.5 Structure of the Report

This report is for completing the ‘Projek Sarjana Muda’ (PSM) with contain chapter

1 until chapter 6 only. The chapter 1 until chapter 3 was done by last semester and

for PSM 2 on this semester consist of chapter 4 until 6.

Chapter 1: This chapter was included about the title of this project, problem

statement, objective of this project, and scope of the project. This will be a guideline

for complete the PSM. In this chapter, there are three objective of this project that

should be study and find.

Chapter 2: This will define about the literature review about the five axis milling

machine. All the process parameter using this machine from the journals and books

provided. In the end of this chapter is a summary of literature review is also

provided.

Chapter 3: Describe an experimental method of this project including Design of

Experiment (DOE), experiment flow, experiment set up and equipment, and

technique used. Introduction on some method and approach in selecting an optimize

parameters for this experimental research also stated in this report. The conclusion of

this chapter would interpret as research flow along this research. The method for this

project can see in Figure 1.1

Chapter 4: In this chapter was describing about the result from the analysis data. The

data got then will use in Design Expert software. This software then will generate the

Graph, Summary, Interaction Plot, Main Effect, and Optimization. Meanwhile, the

parameter was used in this project such as spindle speed and feed rate can see from

the graph and the best setup also can know. Furthermore, this chapter provides

interpretation of experiment result.

Chapter 5: Describe about the response such as surface roughness, dimension

variation, and tool wear. All the response will discuss in this chapter, and will

describe the initial cause. Additionally, the solutions to prevent the cause also have

been described.

Chapter 6: This chapter will describe a conclusion of this research including

interpretation of overall research flow. The overall research objectives, scope,

findings and discussions also conclude in this chapter. Finally, this chapter provides

recommendation of future works.

1.6 Activity Planning

This activity planning will show by using the Gantt chart show in Appendix A and

Appendix B. This will show about the time and the work that have been done in PSM

1 and PSM 2. This Gantt chart is a planning or scheduling operation involving in this

project. By using this chart, it is easy to understand, even though it may contain

information.

1.7 Summary

This chapter is important to run this project. This project had described about the

problem statement, objective, scope, the structure of this report. The objectives of

this project need to achieve after done this project. The objective of this project had

three; firstly, investigate about the surface roughness and dimension variation with

using defined parameter setup, secondly, investigate about the tool wear and lastly

applying the DOE method. Meanwhile, the project also had a scope to focusing in

the certain part that has been described.