Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industr... more Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields especially in aerospace as well as automotive industries due to their excellent mechanical properties such as high strength, low weight and corrosion. The aim of the present work is to investigate the effect of machining parameters on surface quality and cutting forces in edge trimming process for a specific CFRP material. There were two variation of machining parameters focused in this work namely spindle speed (N) and feed per tooth (f z). The range of spindle speed applied was of 2506 rpm (low), 5012 rpm (moderate), and 7518 rpm (high) speed whilst for feed per tooth; 0.05, 0.1, and 0.15 mm/rev. The CFRP panel measured 3.25 mm in thickness and the type of fabric was unidirectional (UD) with 28 number of plies in total has been chosen to be the main study material. Router or burr tool geometry made of uncoated tungsten carbide with a diameter of 6.35 mm was used to perform the edge trimming process. Surface roughness measurement was taken using Mitutoyo Surftest SJ-410. Kistler Type 9257B dynamometer is attached during the edge trimming process to record the cutting forces. The result reveals that the smallest value of the surface roughness (1.62 µm) is obtained by Run 1 (R1) and the highest surface roughness value (12.62 µm) exhibited by the R9. The resultant force exhibits no clear trend on the cutting forces for all the machining parameters applied. However, it is strongly believed that the thermal effect especially the low temperature of glass transition, Tg of the polymer matrix was the main reason affecting the result of the resultant force. Details results elaborated and discussed further in this manuscript.
Over the past twenty years, the level of awarness concerning the importance of accurate and preci... more Over the past twenty years, the level of awarness concerning the importance of accurate and precise shadr alignment has increase dramatically. Therefore shaft alignment seems to have taken more more important role when installing and maintaining machinery. Proper alignment is critical to the life of the machine. Coupling wear or failure, bearing failure, bent rotors or crankshaft, plus bearing housing damage are all common results of poor alignment. When machinery is operating, the moving parts cause friction that in turn creates heat buid-up causing the macinery to expand. this expansion in the machinery is called thermal growth. by neglecting the thermal growth factor, an alignment process changes from simple job into an all dayy affair frequency with unsatifactory result, despite conscientious effort and a considerable in manpower and down time. There a lot of tools on the market to make the mathematics simple, however, a graphic picture shows the whole problem at glance and makes the solution apparent. This paper discussed on the development of shaft alignment procedures using spreadsheet namely as ALIGN. This approach can reduce calculation process and minimize error during shaft alignment process.
Polyetheretherketones (PEEK) have been increasingly employed as biomaterials for trauma, orthoped... more Polyetheretherketones (PEEK) have been increasingly employed as biomaterials for trauma, orthopedic, and spinal implants. These implants are commonly fabricated by extrusion and injection molding, and for this fact, additional machining operations are required. Surface roughness is a vital factor for medical implants since the cells of the surrounding tissue interact with the underlying substrate on the micro and nanometer scales. For some application, such as self-mating articulation cervical disc implants smooth surface finish is critical so as to minimize the contact friction and wear. The requirement for a fine surface roughness poses a major concern in machining of polymeric base materials due to its low thermal conductivity. Machining performance such as surface roughness is directly affected by the milling parameter and should be methodically analyzed. Thus, this paper aims to study the effect of milling parameter on surface roughness of PEEK plastic under dry machining condition. Response Surface Methodology (RSM) technique was used to evaluate the influence of milling parameter namely cutting speed, feed rate and depth of cut on machined surface. From the conducted study, based on the statistical analysis result it is found that feed rate is the main factor that influence the surface roughness followed by milling speed and depth of cut. In addition, optical observation on the machined surface indicated that the mechanisms of the surface finish obtained from machining of polymeric based composites are different from those obtained from machining of the metals. It shows that there is some form of polymeric softening taking place when the cutting speed exceeded a critical cutting speed.
This study is an investigation of tool wear using a ball-type end mill. The primary purpose of th... more This study is an investigation of tool wear using a ball-type end mill. The primary purpose of this work is to examine the tool life and wear mechanism when machining Inconel 718 with a physical vapor deposition (PVD)-coated carbide tool and varying the cutting parameters. Notch wear and flaking near the depth of the cut zone were the predominant types of tool failure for the four round cutting tools and were initiated by pitting caused by the repetitive cyclic load. The major factor identified was the large radial depth of the cut. Further examination indicated that the dominant wear was located near the depth of the cut line. On the flank face, smooth and coarse wear types, from abrasion and attrition, occurred at low and high cutting speeds, respectively. A maximum temperature of 521 1C was recorded, which is less than the critical temperature of 650 1C for Inconel 718. A mathematical model was developed to predict the location of the pitting, which was responsible for notching and flaking. This location could then be used to calculate the location associated with the maximum load exerted during the cutting. The error between the predictive model of pitting and the actual notching/flaking was less than 6%.
Regional Conference on Science, Technology and Social Sciences (RCSTSS 2014), 2016
Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when t... more Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when the depth of cut is less than a minimum chip thickness. This paper presents an investigation of cutting edge radius effect in macro- and micro-machining of AISI D2 steel via simulation using ABAQUS software. Through the arbitrary Lagrangian–Eulerian FE modeling approach, the chip growth, chip formation, and cutting force were investigated under three criteria such as a/r 1, and a/r = 1. The results from this simulation can provide useful information for choosing reasonable cutting edge to improve surface integrity and prolong cutting tool life in macro- and micro-milling operation. It is found that the chip is formed at a/r > 1 while material extrusion performed under a/r < 1. The investigation on the cutting force found that value of a/r ratios greatly affects the cutting force. The cutting mechanism in micro-milling is similar to macro-milling due to the process undergoes both ploughing and shearing mechanism.
This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coa... more This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coated carbide under dry cutting condition. Cutting parameters selected were cutting speed, Vc = 115-145 m/min; feed rate fz = 0.15-0.2 mm/tooth and depth of cut, ap = 0.5-0.75 mm. The result showed the tool life of PVD TiAlN ranged from 11 to 97 min. Full factorial approach was employed to exhibit relationship between parameter input and output. From the analysis, cutting speed was found to be the most significant factor for tool performance followed by feed rate and depth of cut. It was also found that most of failure modes occurred were notch wear and flaking near those found near depth of cut line.
Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integr... more Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integrity at elevated temperatures, but it is well known as a material with poor machinability. This paper presents a study of the performance in high speed machining of TiAlN/AlCrN nanomultilayer PVD coated Inconel 718 with minimum lubrication. Investigations have been made into the effects of cutting speed, feed rate and depth of cut (DOC) on the tool life. A toolmaker's microscope and a scanning electron microscope (SEM) were used to examine the tool wear and chemical attrition, respectively, on the cutting tool during machining. In the machining of aged Inconel 718, the cutting tool experienced attrition, abrasion and notch wear throughout the experiment. Notch wear was found to be the dominant failure mode during milling; this wear appeared severe when localized flank wear reached the critical zone. The influence of radial depth despite the cutting speed, well known as having the most significant effect on tool life, is also discussed.
ABSTRACT In this work, the Sandvik uncoated carbide insert, CNGG 120408-SGF-H13A was used as a cu... more ABSTRACT In this work, the Sandvik uncoated carbide insert, CNGG 120408-SGF-H13A was used as a cutting tool in high-speed turning of titanium alloy Ti-6Al-4V ELI (extra-low interstitial) with hardness of 32 HRC. Wear is one of the problems that cannot be avoided in machining process. Therefore, the objective of this paper was to investigate tool-wear behavior of various cutting-speed values (high-speed range) on the tool life of the cutting tools, especially in finishing titanium alloy. The experiments were performed under flooded coolant condition using water-based mineral-oil. The cutting speeds employed were 120, 170 and 220 m/min. The feed rate was constant at 0.2 mm/rev and the depth of cut was 0.4 mm. Based on the results, the highest cutting speed of 220 m/min caused the highest wear rate. By linking the machine operations and the tool life curves obtained using flank wear data, the wear behavior of uncoated carbide was described.
The main problem associate with the machining of thin-wall component is the wall deflection which... more The main problem associate with the machining of thin-wall component is the wall deflection which resulting in dimensional surface error that leads to part rejection. The magnitude of wall deflection is induced by the cutting force generated during the material removal process which is governed mainly from the selection of cutter path strategies. Therefore, it is necessary to judge the machining performance of a different cutter path prior to actual machining. In this paper, the machining accuracy of three cutter path strategies namely waterline-step, overlapping-step and tree wise-steps for machining thin-wall component were investigated. It was found that there is a variation in wall accuracy for different cutter path strategies. Based on the experimental results waterline cutter path produced the least surface error followed by overlapping and tree-wise steps.
Metal matrix composite is composite material that combines the metallic properties of matrix allo... more Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.
Natural Rubber/EPDM blends were successfully prepared by direct melt compounding method using an ... more Natural Rubber/EPDM blends were successfully prepared by direct melt compounding method using an internal mixer. The significance of MAH grafted EPM (MAH-g-EPM) and compounding parameters were studied via the response surface methodology (RSM) using the two-level full factorial design. The MAH-g-EPM loading, mixing temperature, rotor speed and mixing time were selected as four independent variables. Cure characteristics of scorch time, cure time and maximum torque were selected as the responses. The statistical significance of all variables and their interactions during compounding were analysed using ANOVA. The degree of agreement between experimental results with those predicted by the statistical model was confirmed using constant of determination, R2 with values approaching ~0.99. It was observed in the results, that the incorporation of high loading (10 phr) of MAH-g-EPM has predominantly enhanced the scorch safety time of NR/EPDM blends, as well as increased the modulus of NR/EPDM blends to some extent compared to low loading (5 phr and 7.5 phr). These finding were further supported by the Differential Scanning Calorimetry (DSC) analysis.
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace ... more The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) -coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining.
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface ro... more This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of Inconel 718 when milled under minimum quantity lubrication. The response surface methodology (RSM) was employed in the experiment and a Box-Behnken design was used to determine the cause and effect of the relationship between the control variables and the response. The investigated milling parameters were cutting speed (100, 135 and 170 m/min), feed rate (0.15, 0.2 and 0.25 mm/rev) and depth of cut (0.6, 0.8 and 1.0 mm). The results showed that the interaction between the feed rate, f and the radial depth of cut, a , was the z e primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The quadratic empirical models were developed with a 95% confidence level. The optimum condition required for minimum surface roughness include cutting speed of 136 m/min, feed rate of 0.1 mm/rev, axial depth of cut of 0.5 mm and radial depth of cut of 1.38 mm. With this optimum condition, a surface roughness of 0.117 µm was obtained.
Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industr... more Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields especially in aerospace as well as automotive industries due to their excellent mechanical properties such as high strength, low weight and corrosion. The aim of the present work is to investigate the effect of machining parameters on surface quality and cutting forces in edge trimming process for a specific CFRP material. There were two variation of machining parameters focused in this work namely spindle speed (N) and feed per tooth (f z). The range of spindle speed applied was of 2506 rpm (low), 5012 rpm (moderate), and 7518 rpm (high) speed whilst for feed per tooth; 0.05, 0.1, and 0.15 mm/rev. The CFRP panel measured 3.25 mm in thickness and the type of fabric was unidirectional (UD) with 28 number of plies in total has been chosen to be the main study material. Router or burr tool geometry made of uncoated tungsten carbide with a diameter of 6.35 mm was used to perform the edge trimming process. Surface roughness measurement was taken using Mitutoyo Surftest SJ-410. Kistler Type 9257B dynamometer is attached during the edge trimming process to record the cutting forces. The result reveals that the smallest value of the surface roughness (1.62 µm) is obtained by Run 1 (R1) and the highest surface roughness value (12.62 µm) exhibited by the R9. The resultant force exhibits no clear trend on the cutting forces for all the machining parameters applied. However, it is strongly believed that the thermal effect especially the low temperature of glass transition, Tg of the polymer matrix was the main reason affecting the result of the resultant force. Details results elaborated and discussed further in this manuscript.
Over the past twenty years, the level of awarness concerning the importance of accurate and preci... more Over the past twenty years, the level of awarness concerning the importance of accurate and precise shadr alignment has increase dramatically. Therefore shaft alignment seems to have taken more more important role when installing and maintaining machinery. Proper alignment is critical to the life of the machine. Coupling wear or failure, bearing failure, bent rotors or crankshaft, plus bearing housing damage are all common results of poor alignment. When machinery is operating, the moving parts cause friction that in turn creates heat buid-up causing the macinery to expand. this expansion in the machinery is called thermal growth. by neglecting the thermal growth factor, an alignment process changes from simple job into an all dayy affair frequency with unsatifactory result, despite conscientious effort and a considerable in manpower and down time. There a lot of tools on the market to make the mathematics simple, however, a graphic picture shows the whole problem at glance and makes the solution apparent. This paper discussed on the development of shaft alignment procedures using spreadsheet namely as ALIGN. This approach can reduce calculation process and minimize error during shaft alignment process.
Polyetheretherketones (PEEK) have been increasingly employed as biomaterials for trauma, orthoped... more Polyetheretherketones (PEEK) have been increasingly employed as biomaterials for trauma, orthopedic, and spinal implants. These implants are commonly fabricated by extrusion and injection molding, and for this fact, additional machining operations are required. Surface roughness is a vital factor for medical implants since the cells of the surrounding tissue interact with the underlying substrate on the micro and nanometer scales. For some application, such as self-mating articulation cervical disc implants smooth surface finish is critical so as to minimize the contact friction and wear. The requirement for a fine surface roughness poses a major concern in machining of polymeric base materials due to its low thermal conductivity. Machining performance such as surface roughness is directly affected by the milling parameter and should be methodically analyzed. Thus, this paper aims to study the effect of milling parameter on surface roughness of PEEK plastic under dry machining condition. Response Surface Methodology (RSM) technique was used to evaluate the influence of milling parameter namely cutting speed, feed rate and depth of cut on machined surface. From the conducted study, based on the statistical analysis result it is found that feed rate is the main factor that influence the surface roughness followed by milling speed and depth of cut. In addition, optical observation on the machined surface indicated that the mechanisms of the surface finish obtained from machining of polymeric based composites are different from those obtained from machining of the metals. It shows that there is some form of polymeric softening taking place when the cutting speed exceeded a critical cutting speed.
This study is an investigation of tool wear using a ball-type end mill. The primary purpose of th... more This study is an investigation of tool wear using a ball-type end mill. The primary purpose of this work is to examine the tool life and wear mechanism when machining Inconel 718 with a physical vapor deposition (PVD)-coated carbide tool and varying the cutting parameters. Notch wear and flaking near the depth of the cut zone were the predominant types of tool failure for the four round cutting tools and were initiated by pitting caused by the repetitive cyclic load. The major factor identified was the large radial depth of the cut. Further examination indicated that the dominant wear was located near the depth of the cut line. On the flank face, smooth and coarse wear types, from abrasion and attrition, occurred at low and high cutting speeds, respectively. A maximum temperature of 521 1C was recorded, which is less than the critical temperature of 650 1C for Inconel 718. A mathematical model was developed to predict the location of the pitting, which was responsible for notching and flaking. This location could then be used to calculate the location associated with the maximum load exerted during the cutting. The error between the predictive model of pitting and the actual notching/flaking was less than 6%.
Regional Conference on Science, Technology and Social Sciences (RCSTSS 2014), 2016
Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when t... more Chip formation is a dynamic process that is often nonlinear in nature. A chip may not form when the depth of cut is less than a minimum chip thickness. This paper presents an investigation of cutting edge radius effect in macro- and micro-machining of AISI D2 steel via simulation using ABAQUS software. Through the arbitrary Lagrangian–Eulerian FE modeling approach, the chip growth, chip formation, and cutting force were investigated under three criteria such as a/r 1, and a/r = 1. The results from this simulation can provide useful information for choosing reasonable cutting edge to improve surface integrity and prolong cutting tool life in macro- and micro-milling operation. It is found that the chip is formed at a/r > 1 while material extrusion performed under a/r < 1. The investigation on the cutting force found that value of a/r ratios greatly affects the cutting force. The cutting mechanism in micro-milling is similar to macro-milling due to the process undergoes both ploughing and shearing mechanism.
This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coa... more This article presents the tool wear mechanism when machining Aluminium alloy 6061-T6 with PVD coated carbide under dry cutting condition. Cutting parameters selected were cutting speed, Vc = 115-145 m/min; feed rate fz = 0.15-0.2 mm/tooth and depth of cut, ap = 0.5-0.75 mm. The result showed the tool life of PVD TiAlN ranged from 11 to 97 min. Full factorial approach was employed to exhibit relationship between parameter input and output. From the analysis, cutting speed was found to be the most significant factor for tool performance followed by feed rate and depth of cut. It was also found that most of failure modes occurred were notch wear and flaking near those found near depth of cut line.
Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integr... more Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integrity at elevated temperatures, but it is well known as a material with poor machinability. This paper presents a study of the performance in high speed machining of TiAlN/AlCrN nanomultilayer PVD coated Inconel 718 with minimum lubrication. Investigations have been made into the effects of cutting speed, feed rate and depth of cut (DOC) on the tool life. A toolmaker's microscope and a scanning electron microscope (SEM) were used to examine the tool wear and chemical attrition, respectively, on the cutting tool during machining. In the machining of aged Inconel 718, the cutting tool experienced attrition, abrasion and notch wear throughout the experiment. Notch wear was found to be the dominant failure mode during milling; this wear appeared severe when localized flank wear reached the critical zone. The influence of radial depth despite the cutting speed, well known as having the most significant effect on tool life, is also discussed.
ABSTRACT In this work, the Sandvik uncoated carbide insert, CNGG 120408-SGF-H13A was used as a cu... more ABSTRACT In this work, the Sandvik uncoated carbide insert, CNGG 120408-SGF-H13A was used as a cutting tool in high-speed turning of titanium alloy Ti-6Al-4V ELI (extra-low interstitial) with hardness of 32 HRC. Wear is one of the problems that cannot be avoided in machining process. Therefore, the objective of this paper was to investigate tool-wear behavior of various cutting-speed values (high-speed range) on the tool life of the cutting tools, especially in finishing titanium alloy. The experiments were performed under flooded coolant condition using water-based mineral-oil. The cutting speeds employed were 120, 170 and 220 m/min. The feed rate was constant at 0.2 mm/rev and the depth of cut was 0.4 mm. Based on the results, the highest cutting speed of 220 m/min caused the highest wear rate. By linking the machine operations and the tool life curves obtained using flank wear data, the wear behavior of uncoated carbide was described.
The main problem associate with the machining of thin-wall component is the wall deflection which... more The main problem associate with the machining of thin-wall component is the wall deflection which resulting in dimensional surface error that leads to part rejection. The magnitude of wall deflection is induced by the cutting force generated during the material removal process which is governed mainly from the selection of cutter path strategies. Therefore, it is necessary to judge the machining performance of a different cutter path prior to actual machining. In this paper, the machining accuracy of three cutter path strategies namely waterline-step, overlapping-step and tree wise-steps for machining thin-wall component were investigated. It was found that there is a variation in wall accuracy for different cutter path strategies. Based on the experimental results waterline cutter path produced the least surface error followed by overlapping and tree-wise steps.
Metal matrix composite is composite material that combines the metallic properties of matrix allo... more Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.
Natural Rubber/EPDM blends were successfully prepared by direct melt compounding method using an ... more Natural Rubber/EPDM blends were successfully prepared by direct melt compounding method using an internal mixer. The significance of MAH grafted EPM (MAH-g-EPM) and compounding parameters were studied via the response surface methodology (RSM) using the two-level full factorial design. The MAH-g-EPM loading, mixing temperature, rotor speed and mixing time were selected as four independent variables. Cure characteristics of scorch time, cure time and maximum torque were selected as the responses. The statistical significance of all variables and their interactions during compounding were analysed using ANOVA. The degree of agreement between experimental results with those predicted by the statistical model was confirmed using constant of determination, R2 with values approaching ~0.99. It was observed in the results, that the incorporation of high loading (10 phr) of MAH-g-EPM has predominantly enhanced the scorch safety time of NR/EPDM blends, as well as increased the modulus of NR/EPDM blends to some extent compared to low loading (5 phr and 7.5 phr). These finding were further supported by the Differential Scanning Calorimetry (DSC) analysis.
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace ... more The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) -coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining.
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface ro... more This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of Inconel 718 when milled under minimum quantity lubrication. The response surface methodology (RSM) was employed in the experiment and a Box-Behnken design was used to determine the cause and effect of the relationship between the control variables and the response. The investigated milling parameters were cutting speed (100, 135 and 170 m/min), feed rate (0.15, 0.2 and 0.25 mm/rev) and depth of cut (0.6, 0.8 and 1.0 mm). The results showed that the interaction between the feed rate, f and the radial depth of cut, a , was the z e primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The quadratic empirical models were developed with a 95% confidence level. The optimum condition required for minimum surface roughness include cutting speed of 136 m/min, feed rate of 0.1 mm/rev, axial depth of cut of 0.5 mm and radial depth of cut of 1.38 mm. With this optimum condition, a surface roughness of 0.117 µm was obtained.
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