The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075

The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075

Aerospace industries often use machining while manufacturing aerospace parts. Machining is done using general endmills that have helix angle of 30o. These endmills give mixed machining results of surface roughness and tool wear depending on the tool manufacturer. This research aims to produce endmil...

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Main Author: Jumali, Muhammad Syafik
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/18601/1/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075%2024%20Pages.pdf
http://eprints.utem.edu.my/id/eprint/18601/2/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075.pdf
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id my-utem-ep.18601
record_format uketd_dc
institution Universiti Teknikal Malaysia Melaka
collection UTeM Repository
language English
English
topic T Technology (General)
TJ Mechanical engineering and machinery
spellingShingle T Technology (General)
TJ Mechanical engineering and machinery
Jumali, Muhammad Syafik
The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
description Aerospace industries often use machining while manufacturing aerospace parts. Machining is done using general endmills that have helix angle of 30o. These endmills give mixed machining results of surface roughness and tool wear depending on the tool manufacturer. This research aims to produce endmill with optimum geometry in terms of the helix angle, primary radial relief angle and secondary relief angle. The endmill is tested on Aluminium 7075 and data on surface roughness and tool wear is collected. Endmill with 10 mm diameter of Tungsten Carbide material is used in this research. Helix angle is varied between 30o-60o, primary radial relief angle varied between 5o-9o while secondary relief angle varied between 14o-17o. Helix angle, primary relief angle and secondary relief angle are the variable parameters. Design of Experiment (DOE) using Full Factorial method is used to generate the matrix of endmill design. 8 samples are prepared with 1 replication means 16 end mills are produced in total. An L-shaped part is machined where the surface roughness is measured both radial and axial by using cutting speed of 600 m/min. Tool wear is examined by studying flank wear. The desirable endmill will have a combination of minimal surface roughness and tool wear. The results of this research show that higher helix angle gives higher tool wear, higher axial surface roughness and higher radial surface roughness and vice versa. Higher primary radial relief angle gives higher tool wear, lower radial surface roughness and higher axial surface roughness and vice versa. Higher secondary radial relief angle gives lower tool wear, higher radial surface roughness and lower axial surface roughness and vice versa. The optimum endmill parameter for helix angle, primary relief angle and secondary relief angle is 30o, 9o and 14o respectively. This research will be very valuable for industries involved with machining Aluminium 7075 namely aerospace industries as it will provide the optimum endmill angles in order to machine Aluminium 7075.
format Thesis
qualification_name Master of Philosophy (M.Phil.)
qualification_level Master's degree
author Jumali, Muhammad Syafik
author_facet Jumali, Muhammad Syafik
author_sort Jumali, Muhammad Syafik
title The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
title_short The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
title_full The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
title_fullStr The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
title_full_unstemmed The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075
title_sort influence of tool geometry towards cutting performance on aluminium 7075
granting_institution Universiti Teknikal Malaysia Melaka
granting_department Faculty of Manufacturing Engineering
publishDate 2016
url http://eprints.utem.edu.my/id/eprint/18601/1/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075%2024%20Pages.pdf
http://eprints.utem.edu.my/id/eprint/18601/2/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075.pdf
_version_ 1747833940349026304
spelling my-utem-ep.186012021-10-08T15:36:26Z The Influence Of Tool Geometry Towards Cutting Performance On Aluminium 7075 2016 Jumali, Muhammad Syafik T Technology (General) TJ Mechanical engineering and machinery Aerospace industries often use machining while manufacturing aerospace parts. Machining is done using general endmills that have helix angle of 30o. These endmills give mixed machining results of surface roughness and tool wear depending on the tool manufacturer. This research aims to produce endmill with optimum geometry in terms of the helix angle, primary radial relief angle and secondary relief angle. The endmill is tested on Aluminium 7075 and data on surface roughness and tool wear is collected. Endmill with 10 mm diameter of Tungsten Carbide material is used in this research. Helix angle is varied between 30o-60o, primary radial relief angle varied between 5o-9o while secondary relief angle varied between 14o-17o. Helix angle, primary relief angle and secondary relief angle are the variable parameters. Design of Experiment (DOE) using Full Factorial method is used to generate the matrix of endmill design. 8 samples are prepared with 1 replication means 16 end mills are produced in total. An L-shaped part is machined where the surface roughness is measured both radial and axial by using cutting speed of 600 m/min. Tool wear is examined by studying flank wear. The desirable endmill will have a combination of minimal surface roughness and tool wear. The results of this research show that higher helix angle gives higher tool wear, higher axial surface roughness and higher radial surface roughness and vice versa. Higher primary radial relief angle gives higher tool wear, lower radial surface roughness and higher axial surface roughness and vice versa. Higher secondary radial relief angle gives lower tool wear, higher radial surface roughness and lower axial surface roughness and vice versa. The optimum endmill parameter for helix angle, primary relief angle and secondary relief angle is 30o, 9o and 14o respectively. This research will be very valuable for industries involved with machining Aluminium 7075 namely aerospace industries as it will provide the optimum endmill angles in order to machine Aluminium 7075. UTeM 2016 Thesis http://eprints.utem.edu.my/id/eprint/18601/ http://eprints.utem.edu.my/id/eprint/18601/1/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075%2024%20Pages.pdf text en public http://eprints.utem.edu.my/id/eprint/18601/2/The%20Influence%20Of%20Tool%20Geometry%20Towards%20Cutting%20Performance%20On%20Aluminium%207075.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=100910 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering 1. Agnew, P.J. 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