The experiment was performed on a vertical milling machine using aluminum blocks to observe surface roughness when changing cutting speed and feed rate. Four experiments were conducted with different parameter combinations, and surface roughness was measured after each. It was concluded that lower feed rates and higher cutting speeds produced the smoothest surface, while higher feed rates and lower cutting speeds led to rougher surfaces.
The experiment was performed on a vertical milling machine using aluminum blocks to observe surface roughness when changing cutting speed and feed rate. Four experiments were conducted with different parameter combinations, and surface roughness was measured after each. It was concluded that lower feed rates and higher cutting speeds produced the smoothest surface, while higher feed rates and lower cutting speeds led to rougher surfaces.
The experiment was performed on a vertical milling machine using aluminum blocks to observe surface roughness when changing cutting speed and feed rate. Four experiments were conducted with different parameter combinations, and surface roughness was measured after each. It was concluded that lower feed rates and higher cutting speeds produced the smoothest surface, while higher feed rates and lower cutting speeds led to rougher surfaces.
The experiment was performed on a vertical milling machine using aluminum blocks to observe surface roughness when changing cutting speed and feed rate. Four experiments were conducted with different parameter combinations, and surface roughness was measured after each. It was concluded that lower feed rates and higher cutting speeds produced the smoothest surface, while higher feed rates and lower cutting speeds led to rougher surfaces.
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Abstract
The experiment was performed on vertical milling machine using two aluminum alloy blocks of the size 50X40X25 mm. The experiment is known as Surface Roughness in Milling and the purpose of the experiment was to observe the roughness on the workpieces by changing cutting parameters such as cuttings speed and feed rate. Also, to give students the opportunity to get hands on experience on the practical knowledge of the unit and relate the outcomes to the theory taught in the unit. The results of the experiment were compared and discussed during the group discussions using graphs.
Introduction As this unit involves the study of manufacturing of products using different raw materials. When a product is manufactured it comes out with different finish and surface texture. Sometimes the specific surface roughness of the product is required in order to meet certain fitting requirements. Surface roughness is defined as the micro-irregularities which result due to the production process. (Taylor Hobson, 2019). As the surface roughness is very closely related to the friction between two components of a mechanism in order to obtain proper functionality of the mechanism because if the surface roughness greater or lower than the required values can affect the fitting of the product which in turn reduces the durability of the product. In this experiment milling was performed on two different blocks of aluminum alloy. The experiment was performed on vertical milling machine which allowed us to choose different cutting speeds ranging from 415 to 3600 (rev/min). The experiment was performed four times on different sides of the two aluminum blocks using sharp face milling cutters with changing cutting parameters each time such as cutting speed and feed rate. The purpose of the experiment was to familiarise students how changing of cutting parameters can affect the surface finish of the product. After each experiment we measured the surface roughness using electronic stylus which is an electronic device used in the engineering industry to measure the surface roughness. The stylus pin moves back and forth on the surface and the reading is displayed on the screen. There are other manual methods of measuring the roughness as well such as using surface roughness comparator with which we have to compare the produced surface roughness. But this method does not give us accurate values. After experiment, the students were also asked to compare the results using graphs and draw conclusions on the basis of their findings.
The milling experiment was performed on vertical milling machine as shown in figure 1 above. The machine comes with different cutting speed and feed rate options. The surface roughness of the manufactured piece depends on various factors such as cutting speed, feed rate, material type and sharpness of the milling cutters etc. We performed the experiment 4 times using different combinations of feed rate and cutting speed, the parameters such as cutters and depth of cut were kept constant i.e. 2 mm in this case. The four different surface finishes were attained to examine and study how the change of cutting speed and feed rate can affect the surface roughness of the workpiece. The following formula can be used to calculate cutting speed: πDN v= 1000 Where, N is the spindle speed (rpm); v is the cutting speed (m/min); and D is the diameter (mm). The following equation is used to calculate feed rate (fr):
f r= Nnt f Where, f is the chip load per tooth; f ris the feed rate; nt is the number of teeth of the cutting tool and N is the spindle speed.
Conclusion After detailed discussion on the results we reached to the conclusion that the cutting speed and feed rate has drastic effects on the surface roughness of the product. It was observed that in order attain the smoothest texture with very low surface roughness the cutting speed must be kept very high and feed must be kept to the low value. The increase in the feed rate and decrease in the cutting speed results in the higher surface roughness value and vice versa. However, high cutting speed with low feed rate gives us shinny texture on the finish of the product. Whereas, high feed with low cutting speed gives us dull finish.
Individual Reflection Essay (Ahmed Ali ARSHAD – 10450518)
The laboratory session started with the brief safety induction and then the lab demonstrator explained the functionality of the milling machines and how to perform the experiment safely. The experiment was performed in group of 3 students. We were given two Aluminum alloy blocks of the size 50X40X25 mm as raw materials. The experiment was performed four times in total using each block for two times. The experiment was performed with different cutting parameters each time such as feed rate and cutting speed. We were asked to select cutting parameters from the given values on the table. We chose two feed rates with one of high value of 653 mm/min and the other of low value of 27 mm/min. The cutting speeds were selected as 580 and 3230 rev/min as low and high cutting speeds respectively. The depth of the cut was kept constant at 2 mm throughout the experiment. We followed the instructions sheet to form 4 different combinations of cutting speed and feed rate. After the experiment was completed, we calculated the surface roughness values using the stylus and the results of the experiment were compared and discussed within the group. A conclusion was drawn in the end based on the discussion and results of the experiment. After this experiment we learned that how cutting parameters can affect the surface roughness of the product. The surface roughness plays a vital role when it comes to assembling the parts. In order to attain the desired fitting, the surface roughness has to be of specific value for the mechanism to work properly and to ensure the durability. In this experiment, we were not offered the opportunity to create the assembly or mechanism by manufacturing the parts. Which would have been very beneficial to fully understand how the surface roughness influence the working of the mechanisms. However, working as a team with other students helped us sharing views and drawing more accurate conclusions. (Word count= 322)
Surface Roughness Analysis in Machining of Glass Fiber Reinforced Epoxy Composite With Carbide Tool Using Taguchi A. K. Parida Volume - 1, Number - 1 Publication Year: 2012, Page(s) : 67 - 73
