Effect of Machining Parameters on Machining Performance during End Milling
摘要
End milling is one of the most often utilized face milling operations in the metalworking industry for creating slots, cavities, and complex profiles from any kinds of work piece material. However, productivity, and quality of the component produced by this process are enhanced by the suitable selection of machining variables. The current study investigates the effect of change of process variables such as feed rate, spindle speed, cutting depth, and coolant concentration on material removal rate, material hardness, and average surface roughness for cutting slots in AISI 1040 Carbon Steel. A total of 16 set of end mill experiments were conducted, using four levels for each machining variable using a 3-axis Vertical Milling Machine. The key finding of this investigation is that AISI 1040 Carbon Steel could be able to capture the performance measure within the expected range over the wide range of machining variables. Specifically, end milling operations improve productivity (i.e., material removal rate of 483.9 mm3/min) at a higher cutting depth (i.e., 0.75 mm) and achieve a better surface finish (i.e., 4.86 μm) at a lower cutting depth (i.e., 0.1 mm) among other machining variables. This work suggests the improvement of ductility without compromising productivity or surface finish at a hardness of 75.4 HRB. Moreover, the investigation offers the formation of a long, tightly curled appearance of chips with a lesser radius of curvature at higher concentrations of coolant.