Microcutting performance monitoring – investigation on tool failure criterion

In recent years, there is an increasing demand for miniaturized components from various industries, such as biomedical, aerospace, electronics, automotive, and military industries, due to their technology advancement. As the technology advanced, the trend shows the components had become smaller and...

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Main Author:	Ainur Munira, Rosli
Format:	Thesis
Language:	English
Published:	2022
Subjects:	TA Engineering (General) Civil engineering (General) TS Manufactures
Online Access:	http://umpir.ump.edu.my/id/eprint/36823/1/ir.Microcutting%20performance%20monitoring%20%E2%80%93%20investigation%20on%20tool%20failure%20criterion.pdf
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spelling	my-ump-ir.368232023-09-14T06:46:06Z Microcutting performance monitoring – investigation on tool failure criterion 2022-05 Ainur Munira, Rosli TA Engineering (General). Civil engineering (General) TS Manufactures In recent years, there is an increasing demand for miniaturized components from various industries, such as biomedical, aerospace, electronics, automotive, and military industries, due to their technology advancement. As the technology advanced, the trend shows the components had become smaller and lighter but still carry out the same or more improved function. One of the processes that can create intricate small components is the microcutting process, where it can create micro sized components or prototype with cost effective and high-quality end product. However, the specific micro machining machine itself is expensive to own rather than using the conventional end milling machine that was already owned to carry out a microcutting process. In order to make this happen, this research studies the tool wear behaviour during low-speed microcutting of aluminium alloy 6065 and AISI 1045 steel material, where a tungsten carbide (wc) tool of 1.0mm and four flute is utilized. This is because we recognize that one of the essential factors in microcutting process is the micro cutting tool itself. The tool failure or wear effects the cost, average surface roughness, functionality, and the quality of the finished product greatly. The research is conducted under different cutting condition with varying feed rate of 0.001mm/tooth to 0.005mm/tooth and cutting speed of 3.142m/min to 9.425m/min using side milling process where the side flank face wear progression of the tool is measured. Then, the average surface roughness and chip size data are collected using a 3D laser measurement microscope. Based on the results, there is a similar tool wear trend of the microcutting process with the conventional methods. The tool shows more rapid wear rate and reduced tool life during micro cutting of AISI 1045 steel as it has higher material hardness compared to aluminium alloy 6065 although the machining process is still achievable. The premature tool failure of low-speed microcutting process is often focused on the entrance of the workpiece. Other than that, it is found that there are some instances where the average surface roughness had decreased abruptly when it is reaching the fracture zone, which is caused by the geometrical effect from the worn edge of the tool. This could be applied in future design of the micro tool suitable for low-speed machining. It is also concluded that appropriate selection of machining conditions has the potential to reduce tool wear rate and encourage longer tool life. 2022-05 Thesis http://umpir.ump.edu.my/id/eprint/36823/ http://umpir.ump.edu.my/id/eprint/36823/1/ir.Microcutting%20performance%20monitoring%20%E2%80%93%20investigation%20on%20tool%20failure%20criterion.pdf pdf en public masters Universiti Malaysia Pahang Faculty of Manufacturing and Mechatronic Engineering Technology Ahmad Shahir, Jamaludin
institution	Universiti Malaysia Pahang Al-Sultan Abdullah
collection	UMPSA Institutional Repository
language	English
advisor	Ahmad Shahir, Jamaludin
topic	TA Engineering (General) Civil engineering (General) TS Manufactures
spellingShingle	TA Engineering (General) Civil engineering (General) TS Manufactures Ainur Munira, Rosli Microcutting performance monitoring – investigation on tool failure criterion
description	In recent years, there is an increasing demand for miniaturized components from various industries, such as biomedical, aerospace, electronics, automotive, and military industries, due to their technology advancement. As the technology advanced, the trend shows the components had become smaller and lighter but still carry out the same or more improved function. One of the processes that can create intricate small components is the microcutting process, where it can create micro sized components or prototype with cost effective and high-quality end product. However, the specific micro machining machine itself is expensive to own rather than using the conventional end milling machine that was already owned to carry out a microcutting process. In order to make this happen, this research studies the tool wear behaviour during low-speed microcutting of aluminium alloy 6065 and AISI 1045 steel material, where a tungsten carbide (wc) tool of 1.0mm and four flute is utilized. This is because we recognize that one of the essential factors in microcutting process is the micro cutting tool itself. The tool failure or wear effects the cost, average surface roughness, functionality, and the quality of the finished product greatly. The research is conducted under different cutting condition with varying feed rate of 0.001mm/tooth to 0.005mm/tooth and cutting speed of 3.142m/min to 9.425m/min using side milling process where the side flank face wear progression of the tool is measured. Then, the average surface roughness and chip size data are collected using a 3D laser measurement microscope. Based on the results, there is a similar tool wear trend of the microcutting process with the conventional methods. The tool shows more rapid wear rate and reduced tool life during micro cutting of AISI 1045 steel as it has higher material hardness compared to aluminium alloy 6065 although the machining process is still achievable. The premature tool failure of low-speed microcutting process is often focused on the entrance of the workpiece. Other than that, it is found that there are some instances where the average surface roughness had decreased abruptly when it is reaching the fracture zone, which is caused by the geometrical effect from the worn edge of the tool. This could be applied in future design of the micro tool suitable for low-speed machining. It is also concluded that appropriate selection of machining conditions has the potential to reduce tool wear rate and encourage longer tool life.
format	Thesis
qualification_level	Master's degree
author	Ainur Munira, Rosli
author_facet	Ainur Munira, Rosli
author_sort	Ainur Munira, Rosli
title	Microcutting performance monitoring – investigation on tool failure criterion
title_short	Microcutting performance monitoring – investigation on tool failure criterion
title_full	Microcutting performance monitoring – investigation on tool failure criterion
title_fullStr	Microcutting performance monitoring – investigation on tool failure criterion
title_full_unstemmed	Microcutting performance monitoring – investigation on tool failure criterion
title_sort	microcutting performance monitoring – investigation on tool failure criterion
granting_institution	Universiti Malaysia Pahang
granting_department	Faculty of Manufacturing and Mechatronic Engineering Technology
publishDate	2022
url	http://umpir.ump.edu.my/id/eprint/36823/1/ir.Microcutting%20performance%20monitoring%20%E2%80%93%20investigation%20on%20tool%20failure%20criterion.pdf
_version_	1783732253971447808

Microcutting performance monitoring – investigation on tool failure criterion

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