Analyze Tool Wear of Cemented Tungsten Carbide End Mill 2T, 3T, 4T

for Output of Force and Temperature Data using Third Wave

AdvantEdge Software Simulation

SCIENTIFIC PUBLICATION

Arranged as a requirement to complete Undergraduate Study Program in

Mechanical Engineering, Engineering Faculty

By:

BRILIAN REXA BUANA D200133008

MECHANICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY

UNIVERSITAS MUHAMMADIYAH SURAKARTA

2017

APPROVAL SHEET

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APPROVAL SHEET

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Analyze Tool Wear of Cemented Tungsten Carbide End Mill 2T,

3T, 4T for Output of Force and Temperature Data using Third

Wave AdvantEdge Software Simulation

1Brilian Rexa Buana, 2Wijianto, 3Feng Qing

1Bachelor Student, Dept. of Mechanical Engineering, Wuxi Institute of Technology,

China, 2Mechanical Engineering Universitas Muhammadiyah Surakarta, 3Mechanical

Engineering Wuxi Institute of Technology. brilianrexa12@gmail.com

ABSTRACT

Tool wear is one of the most important topic in cutting field. Its interest is

due to the influence of tool wear on surface integrity of the final parts and on tool

life, and, consequently, on the substitution policies and production costs. The

methods of process of cutting tool design has been massively used in industrial

world. Based on the seeking the best performance needs of production, it is crucial

to set up the proper cutters. Variations of cutting tool of 2 flute and 3 flute End

Mill Cemented Tungsten Carbide Material with serial type of YT15(P10) by

diameter 6mm, 8mm, 10mm, respectively are tested using FEM method using

simulation of Finite Element Analysis Software which is Third Wave AdvantEdge

to predict the cutting force, temperature tested on Stainless Steel AISI 1045. It also

accumulated with 4 flute End Mill. Comparing those for seeking the best performance production and machining parameters by manufacturing process

Keausan alat adalah salah satu topik yang paling penting dalam bidang

pemotongan. Hal tersebut terjadi karena pengaruh keausan alat pada integritas

permukaan bagian akhir dan pada umur alat, dan akibatnya, pada kebijakan

substitusi dan biaya produksi. Metode proses perancangan alat potong telah

banyak digunakan di dunia industri. Berdasarkan pada mencari kebutuhan

produksi terbaik, sangat penting untuk memasang pemotong yang tepat. Variasi

alat pemotong 2 flute dan 3 flute End Mill berbahan Cemented Tungsten Carbide

dengan tipe seri YT15 (P10) dengan diameter 6mm, 8mm, 10mm, masing-masing

diuji dengan menggunakan metode FEM dengan menggunakan simulasi

Perangkat Analisis Elemen Hingga yang merupakan Third Wave AdvantEdge

Untuk memprediksi kekuatan pemotongan, suhu yang diuji pada Stainless Steel

AISI 1045. Ini juga terakumulasi dengan 4 flute End Mill. Membandingkan

mereka yang mencari parameter produksi dan parameter permesinan terbaik

dengan proses manufaktur

Key words: Force (gaya), Temperature (temperature), Tool Wear (keausan

alat), Third Wave Systems AdvantEdge, AISI 1045, 2 Flute and 3 Flute Carbide

End Mill.

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INTRODUCTION

In The revolution in the industrial world especially at section of science and

technology can be sensed at this age. The sense of knowing the improvement of

production which has better quality one step at the time and its application. During the

moment, the fields of engineering is progressing rapidly. The education of mechanical

technology needs to address the challenges of progress. The production process or the

subjects studies Mechanical Technology, in case to acknowledge an understanding to be

able to practice into the world of work, especially in production machinery. Within the

needs of reverse engineering with significantly developing, the time comes to have more

understanding and application.

Since the Industrial Revolution, manufacturing has been synonymous with factories,

machine tools, production lines and economies of scale. So it is startling to think about

manufacturing without tooling, assembly lines or supply chains. However, this is exactly

what is happening as milling manufacture reaches individuals, small businesses and

corporate departments.

End milling is a very common operation performed on both vertical and horizontal

spindle milling machines or machining centers. For a vertical spindle end milling process,

cutting a step in the workpiece. This cutter can cut on both sides and ends of the tool. If

the operator was performing this operation on a block of metal, it would be the best to

select a specific machine tool. Operator would has to determine how many passes (rough

and finish cuts) were needed to produce the geometry specified in the design. Due to the

number of passes determines the total cutting time for the job (DeGarmo, P. et al., 2008).

The tool material and cutter geometry must be designed to withstand these conditions.

Some researches defined that energy consumption of machine tool has been the

crucial issues in some years. Therefore to obtain the best result of energy consumption in

machine tools and manufacturing systems is understanding and characterize them. In

general, the energy consumption of spindle system is the majority of energy consumption

of machine tool and varies instantly with various types of manufacturing activities. (Hu,

S., 2010). The rate of feed, or the speed at which the workpiece passes the cutter,

determines the time required for cutting a job. Thus, forces are exerted against the

workpiece, the cutter, and their holding devices during the cutting process. The force

exerted varies directly with the amount of metal removed and can be regulated by the

feed and the depth of cut. (AIPD, 1988)

A classical approach has been to develop milling mechanics models that the

geometric model must also include the cutting edge geometry along the flutes for

analyzing the mechanics and dynamics of the milling process. The prediction of the

cutting forces and vibrations require the coordinates, as well as rake, helix, clearance

angles of the cutting edge point on the flute (Engin, S., 2016). Therefore, based on the

description above, an amazing interest of modelling the tools which suites the most then

simulation for manufacturing process in order for comparison of the best result

ANALYZE METHOD

At section of experimental design the workpiece material was AISI 1045 steel in the

form of bars having 80 mm length and height of 50 mm also width of 40 mm. AISI 1045

steel was selected due to its emergent range of applications in the field of manufacturing

tools in mould industries.

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Figure 1 Part Speciment of AISI 1045.

Post-procedure the simulation on Third Wave AdvantEdge Soft. for finding optimum

parameter process. It can be concluded that after several different geometries of cutting

tools on 2 Flute 3 Flute End Mill, the most optimum tool wear that suites the most with the

operation and tool life for surface finish cutting process is 2 Flute. The real machining

treatment able to be used of becoming the initial data parameter for next reference or

consideration

Referenced to Nachi America Inc. In order to select appropriate end mill geometry, 3

types of models have been created using CAD software Solidworks 2015 Soft with each

different parameter. In order to decrease the computational resources required for

numerical analysis, the entire model of the twist drill were cleaned up from unnecessary

features. The authors are not allowed to present the exact values of all parameters of end

mill geometry, because of manufacturer different grades.

Figure 2 3D Solid Modeling Flute End Mill on Solidwork 2015; 2 Flute, 3 Flute, side

views.

All of preparation and consideration are used to realize the result of optimalization

by simulation. And the real machining treatment are used to become initial data

parameter for the next consideration. And all the equipment beside those already

explained above others are

Initial simulation. Exact effect of tool wear with selected machining. The parameter

above is used to looking for the tool wear before optimization. So, it’s become first data

or common data of initial parameters. 3D plug milling simulation is use to know the tool

wear both of three types of tools.

Simulation and experiment 1. Finding optimal feed rate by TWS simulation.

Because rough process are so complicated path line, the simulation taken by using 3D

pocket milling.

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Table 1 Milling Process Parameters for Analysis

At this case, simulation was performed on 2 flute and 3 flute. Since the result shown

from tecPlot, the best tools required with machining parameter is 2 flute.

To prove that the modeling matched on the parameters for the first 2 and 3 flutes

end mill. Therefore, it is unnecessary to perform simulation on 4 flute end mill modeling.

The data recommendation below is used on observing the continuous changing data

for optimization parameter’s process without ignoring tool life. Based on the result of

simulation. Now it is continued to experiment with 2 Flute with diameter of 6 and 10

mm respectively, along with the 4 Flute with diameter of 6, 8, 10 mm. regarding the

objective research towards the tool wear, surface finish milling machine is an option at

this case.

Table 2 Selected Machining Parameter

Therefore, it is continued to experiment with 2 Flute with diameter of 6 and 10 mm

respectively, along with the 4 Flute with diameter of 6,8, 10 mm. regarding the objective

research towards the tool wear, surface finish milling machine is an option at this case.

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DISCUSSION ANALYZE

Figure 3 result of simulation. (a).chip shape temperature. (b). Thrust Force. (c).

Peak Tool Temperature

Regarding the figures shown above the temperature field distribution of chips

produced by 2T and 3T with each different dimension respectively are shown. The

temperature over the chips varies from 200°C to 550°C and are the same for both

geometries. However what is more surprising is that the difference of flutes in cutting

tool between 2 Flute and 3 Flute didn’t change the shape of produced chip significantly.

Figures of thrust force above are the comparison of thrust force between those

geometries is provided. It is obvious that geometries generated the different magnitudes

of thrust force. The different magnitudes of thrust force also support the results by

analysis of chip shape and temperature field distribution presented. Based upon results

from numerical analysis the model of 2 Flute End Mill with diameter 8 mm was selected

because of better direction of chip in to the flute of solid end mill.

The figures above are shown the temperature field distribution on end mill’s cutting

edge. From the figures are obvious that the temperatures rise from center to outer

diameter of cutting edge. The table 4.3 shown the connection of the peak tool temperature

with thrust force, all temperatures has range of 245 ᵒC to 400 ᵒC.

However the temperature of different geometries are produced by low thrust force.

Regarding the theory to the fact that increased feed rate led to a corresponding change in

temperature, leading to shorter tool life. But if low speed is used the cutting temperature

will be lower than the optimal cutting temperature, leading to longer tool life, an increase

in the cutting feed lead to a decrease in tool life. Therefore, within the range can be

concluded that there are no significant peak tool temperature and have no effect on tool

wear

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Table 3 Experimental Result Value on Material AISI 1045 Steel

In general, wear could be defined as the undesirable and continuous loss of the

material from a solid surface due to mechanical interactions such as contact and relative

motion between two bodies (Nahak, S. et al., 2015).

Table 4 Measurement Value on Cutting Tool Wear After Experiment

For AISI 1045 stainless steel various parameters like cutting forces in x, y & z

direction, surface finish and tool wear are experimentally found out. For milling speed to

5308 rpm, 3980 rpm, 3185 rpm and feed rate of 1062 mm/min, 796 mm/min and 319

mm/min respectively. However, regarding the theory. The choice has made towards the

4 Flutes with diameter of 8 mm.

CONCLUSION

1. The observation has led to the first outcome of nature drill’s flute which is chip

shape temperature, the temperature over the chips varies from 200° to 550° C, which is

in the safe range. The tecplot has underestimate the outcome of the chip shape compared

to the experiment result which in actual has no significant change.

2. The form of cutting tool with less number tooth could lead to a better chip

ejection and have less rigidity. In other way, the more number of tooth could lead to

worse chip ejection with high rigidity. However what is more surprising is that the

difference of flutes in cutting tool between 2 Flute and 3 Flute didn’t change the shape

of produced chip significantly. The only difference is visible in change on the 3 Flute

has slightly different shape than 2 Flute which prove the theory of better chip ejection.

3. Figures of thrust force above are the comparison of thrust force between those

geometries listed on Table 4.2 is provided. It is obvious that geometries generated the

different magnitudes of thrust force. The best performance is shown on Table 4.2 the 2T

with Diameter of 8mm 126.893 N, followed by the 3T of 8 mm, 2T and 3T of 6 mm, and

the last is 2T and 3T of 10 mm.

4. This has proven the theory to the fact that increased feed rate led to a

corresponding change in temperature, leading to shorter tool life. But if low speed is used

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the cutting temperature will be lower than the optimal cutting temperature, leading to

longer tool life, an increase in the cutting feed lead. to a decrease in tool life. Therefore,

within the range can be concluded that there are no significant peak tool temperature and

have no effect on tool wear, all temperatures has range of 245 ᵒC to 400 ᵒC.

5. Performance of Surface Roughness (Ra), µm in order to have better quality of

machining in Finish Milling when the two most significant factors are at their better level,

4 Flutes with diameter of 8 mm has good surface quality by the value of (Ra), µm=0.587.

Followed by, 2 Flutes with diameter of 6 mm with better surface quality by the value of

(Ra), µm=0.421.

6. For AISI 1045 stainless steel various parameters like cutting forces in x, y & z

direction, surface finish and tool wear are experimentally found out. For milling speed

to 5308 rpm, 3980 rpm, 3185 rpm and feed rate of 1062 mm/min, 796 mm/min and 319

mm/min respectively. However, regarding the theory explained on chapter 2. The choice

has made towards the 4 Flutes with diameter of 8 mm.

7. The predicted optimal range of tool wear is 0.013 ≤ µTW ≤ 2.029. Yet the

measurement was conducted by micrometer and recorded 0.01 ≤ µTW ≤ 0.1.

8. Measurement of temperatures at nano-scale is practically not possible, therefore

Thirdwave is used for predicting the value before the experiment in order to avoid failure

in machining and reduce cost time and cost in machining.

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