The effect of cutting parameter, surface integrity and tool wear on AISI D2 tool steel in dry milling process

• Main Author: Juwara, Luqman Nul Hakim
• Format: Thesis
• Language: English; English
• Published: 2016
• Subjects: T Technology (General); TJ Mechanical engineering and machinery
• Online Access: http://eprints.utem.edu.my/id/eprint/20456/1/The%20effect%20of%20cutting%20parameter%2C%20surface%20integrity%20and%20tool%20wear%20on%20AISI%20D2%20tool%20steel%20in%20dry%20milling%20process.pdf; http://eprints.utem.edu.my/id/eprint/20456/2/The%20effect%20of%20cutting%20parameter%2C%20surface%20integrity%20and%20tool%20wear%20on%20AISI%20D2%20tool%20steel%20in%20dry%20milling%20process.pdf; http://eprints.utem.edu.my/id/eprint/20456/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=104968

Surface integrity and tool wear has become a very significant consideration in order to achieve optimum cutting parameter along with the recent evolutions in hard milling technology.This project was conducted to study the effect of cutting parameters on tool wear and surface roughness using AISI D2 tool steel in dry milling process. HAAS CNC Milling Machine was utilized in this project to remove the material surface.The parameters that had been selected were cutting speed,feed rate and depth of cut.A dry milling process was conducted during the machining process. The cutting tool that had been selected was TiAIN coated carbide endmill.The diameter of the cutting tools is 10 mm.AISI D2 tool steel was selected as the work piece material.The size of the material is 50 mm x 40 mm with 30 mm thickness.The design of experiments in this project was using the Taguchi method with L9 of orthogonal array.Then, by using the Mitutoyo surface roughness tester with ten points tested,the average surface roughness were measured. The surface integrity of the workpiece and the tool wear rate of the cutting tool were later analysed using the stereo microscope.In order to determine the optimum machining parameter,Taguchi method was used by using Minitab 17 software.This analysis was conducted to identify which cutting parameter that significantly affected the surface roughness and the tool wear rate.From the analysis, the optimum cutting parameter to get the minimum surface roughness is cutting speed is 200 m/min,the feed rate is 0.015 mm/tooth and depth of cut is 0.1 mm.It shows that the feed rate is the most influence parameter that contributed the highest effect of surface roughness and followed by the cutting speed and depth of cut.The optimum cutting parameter that contributes to the lowest tool wear is cutting speed is 150 m/min,feed rate is 0.010 mm/tooth and depth of cut is 0.2 mm.The obtained results showed that the depth of cut has a significant influence on the tool wear rate.As for the surface integrity,the workpiece surface with lowest surface roughness shows the less existence of feed marks on the machined surfaced workpiece.The low value of depth of cut assists in obtaining a finer surface finish.