1. Investigation of machining parameter for face milling operations on various materials Members:- P.Abupakkar sidhic, (80107144002) J.Kavirajan, (80107144019) S.Manikandan, (80107144022) R.H.Raaj Kumar. (80107144034) Guided by : Mr. S.Kannan.,M.E. Associate Professor

2. Project description In our project we are going to analyze the machining parameters such as MRR,SPEED,FEED,DEPTH OF CUT and also the corresponding SURFACE FINISH for the FACE MILLING operation. Also we are going analyze the COST INVOLVED and MACHING TIME associated with the process.

3. Face Milling: A milling operation in which the surface of the workpiece is perpendicular to the spindle axis. Face milling primarily is used to mill the top surface of the part.

4. Face milling job and cutter

5. High Speed Steel properties High Speed Steel is a multi-component alloy carbon-based steel and, as such, steel mills manufacture HSS according to the Fe-C-X system (Iron-Carbon-X). In this system, "X" can represent one or more other elements, most commonly Tungsten plus chromium, molybdenum, vanadium, or cobalt. High Speed Steel exhibits a density of 8.67x1000 kg/m3 (kilograms per meters-cubed). A greater percentage of chromium in HSS alloys will increase its strength, while vanadium increases will improve the cutting quality and sharpness of tools and drill bits made with HSS. When used in tools, High Speed Steel operates at a very low thermal expansion rate of 9.7 microns per meter per degree Celsius. It also conducts heat at a very low rate.

6. carbide tool:

7. Carbide Tool Properties Carbide is in the range of twice that of tool steel and carbon steel. carbide is in the same range as tool steel and carbon steel. Tungsten carbide's low thermal expansion rate must be carefully considered when preforms are provided for grinding or EDM. Carbide compositions exhibit low dry coefficient of friction values as compared to steels. Conventional grades have sufficient resistance to corrosion-wear conditions for many applications.

8. Methodology Operation: Face milling Materials We are going to perform our task on the material Aluminium, Copper, Tool used High speed steel Carbide.

9. Parameters : Input i.Speed ii.Feed iii.Depth of cut Find out: i.Material Removal Rate ii.Machining Time iii.Machining Cost iv.Surface roughness

10. specification work piece : Shape - Cube size - 32x32x32 mm

11. Vertical milling machine

12. Machine specificationMode –super mini mill Travel: x-axis y axis z axis 406 mm 305mm 254mm Table dimension: length width 914mm 730mm Spindle : speed max.motor rating 0-10000rpm 11.2kw Feed rates: maximum rapids max cutting 30.5m/min 21.2m/min Tool : capacity type max.tool diameter max. tool weight 10 CT40 89mm 6.4kg Accuracy : positioning repeatability +/- 0.0051mm +/-0.0025mm Gentral:power15kw

13. Surface testing Surface testing machine is used by us for the measurement of all the machined surface on the material. The roughness should be in the range of “microns” The capacity of surface tester is ranges from 10 – 100 microns

14. Software used: “DESIGN EXPERT”.

15. WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase 1 11000.5100.25 30X33 2 1100.34 30X30 3 1.5100.28 30X30 4190015000.590.69 30X30 5 190.74 31X33 6 1.590.62 33X31 7 22000.581.04 33X30 8 171.23 30X30 9 1.580.80 30X30 10 15000.590.76 32X31 11 190.24 31X31 12 1.590.3 31X31 13250020000.570.4 29X31 14 170.14 29X31 15 1.570.73 31X31 16 25000.570.31 31X31 17 170.84 31X31 18 1.571.1 31X31 19 19000.580.16 31X31 20 180.13 31X31 21 1.580.16 30X30 22 22000.570.13 30X30 233200170.51 32X32 24 1.570.15 31X31 25 28000.570.18 31X31 26 170.23 31X33 27 1.570.24 31X32

16. WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase λ=3 112008000.5164.85 32x32 21163.23 31x33 31.5163.76 31x33 410000.5144.22 30x33 51144.63 30x30 61.5142.29 30x30 712000.5134.28 33x32 81133.82 33x31 91.5125.02 33x31 1013508000.5165.03 33x30 111155.13 30x30 121.5154.69 30x30 1310000.5143.65 32x32 141 3.45 32x32 151.5144.04 31x33 1612000.5124.2 31x30 171124.78 30x31 181.5143.88 31x30 1915008000.5166 33x32 201163.95 32x31 211.5163.09 31x33 2210000.5145.02 30x32 231144.51 30x30 241.5143.93 30x30 2512000.5124.91 32x33 261124.03 31x32 271.512

17. WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase 19505700.515 1.07 34X32 2115 0.84 31X32 31.516 1.65 34X32 47000.513 0.61 30X32 5113 1.18 30X31 61.513 1.40 32X32 78500.512 1.82 34X34 8112 1.96 30X33 91.512 1.8 33X30 1012007000.513 1.56 29X33 11113 1.59 29X29 121.514 1.20 29X29 139000.512 1.26 33X32 14112 1.25 32X32 151.512 1.98 33X31 1611000.510 2.1 30X33 17110 1.38 31X30 181.510 2.49 30X31 19 8400.512 1.22 32X33 20 112 1.04 33X32 21 1.512 0.81 33X31 22 10200.511 1.32 30X33 231400111 1.72 31X30 24 1.511 1.6 30X31 25 13000.59 1.72 32X33 26 110 2.33 33X32 27 1.510 1.28 31X33

18. WorkSpeedFeedDepth Of CutMachining time RoughnessMaterial Removal Rate (mm 3 ) Job sizeMachining cost piece(rpm)(mm/min)(mm)(sec)(Microns)(mm)(Rs.) phase 16001250.5630.85 33x32 20.75620.42 33x32 31630.77 31x33 41500.5531.12 30x33 50.75520.95 31x30 61540.62 31x31 71750.5450.71 32x32 80.75470.81 32x32 91470.56 33x32 107001250.5630.46 31x33 110.75620.29 31x31 121630.5 31x31 131500.5520.48 32x32 140.75530.43 32x32 151540.24 32x31 161750.5460.23 31x33 170.75450.26 31x30 181470.14 31x30 198001250.5620.53 33x32 200.75630.17 31x33 211630.24 33x31 221500.5530.39 30x33 230.75520.2 31x30 241540.34 30x30 251750.5450.32 32x33 260.75470.22 32x33 271460.37 31x33

19. Formulae MATERIAL REMOVAL RATE, MRR = f*w*d.o.c (mm 3 /min) Where, f=feed in mm/min w=width of job in mm d.o.c=depth of cut in mm

20. Graphical analysis : aluminum in carbide tool at constant d.o.c

21. aluminum in carbide tool at constant speed

22. aluminum in carbide tool

25. aluminum in hss tool at constant d.o.c

26. aluminum in hss tool at constant speed

27. aluminum in hss tool

30. Copper in carbide tool

35. Copper in hss tool

40. analysis The MRR has to be calculated and resultant mrr graphs has yet to be drawn for analysis. Thus the graphical output is taken and we are going to analyse and compare the output with the help of design expert software.

41. Scope We can analyze machining parameters for face milling operation. We can study the cost involved and degree of accuracy associated with it. By doing the above analysis, we can get a ideal solution for the selection parameters of the face milling operation, so that it can be standardized. So surface finish,machining cost and machining time can be improved easily. Hence the selection of such parameters can be made easier in industries with the help of our analysis.

42. DURATION: Machining - 5 days (PRIME CNC INDUSTRY - Coimbatore) Surface testing - 3 days (ANNAMALAI UNIVERSITY- Chidambaram ) Analyzing - 5 days Result analysis - 2 days TOTAL - 15 DAYS

43. Conclusion the Investigation of machining parameter for face milling operations on various materials is under progress. Thus in our project the machining parameters for the FACE MILLING operation is analysed. The COST INVOLVED and MACHING TIME associated with the process is analysed. By doing the above analysis, the selection parameters of the face milling operation is yet to be standardized.

44. Thank you