The effect of spindle speed, feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation

Title
The effect of spindle speed, feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation
Author(s)
고태조G. Kiswanto[G. Kiswanto]D.L.Zariatin[D.L.Zariatin]
Keywords
ANGLE
Issue Date
201410
Publisher
ELSEVIER SCI LTD
Citation
JOURNAL OF MANUFACTURING PROCESSES, v.16, no.4, pp.435 - 450
Abstract
This paper describes the characteristics and the cutting parameters performance of spindle speeds (n, rpm) and feed-rates (f, mm/s) during three interval ranges of machining times (t, minutes) with respect to the surface roughness and burr formation, by using a miniaturized micro-milling machine. Flat end-mill tools that have two-flutes, made of solid carbide with Mega-T coated, with 0.2 mm in diameter were used to cut Aluminum Alloy AM 100. The causal relationship among spindle speeds, feed-rates, and machining times toward the surface roughness was analyzed using a statistical method ANOVA. It is found that the feed-rate (f) and machining time (t) contribute significantly to the surface roughness. Lower feed-rate would produce better surface roughness. However, when machining time is transformed into total cut length, it is known that a higher feed-rate, that consequently giving more productive machining since produce more cut length, would not degrade surface quality and tool life significantly. Burr occurrence on machined work pieces was analyzed using SEM. The average sizes of top burr for each cutting parameter selection were analyzed to find the relation between the cutting parameters and burr formation. In this research, bottom burr was found. It is formed in a longer machining time compare the formation of top burr, entrance burr and exit burr. Burr formation is significantly affected by the tool condition, which is degrading during the machining process. This knowledge of appropriate cutting parameter selection and actual tool condition would be an important consideration when planning a micro-milling process to produce a product with minimum burr. (C) 2014 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
URI
http://hdl.handle.net/YU.REPOSITORY/30606http://dx.doi.org/10.1016/j.jmapro.2014.05.003
ISSN
1526-6125
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공과대학 > 기계공학부 > Articles
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