Enhancement of Cutting Tool Performance in Cnc Turning through Innovative Designs

Abstract

The imperative objective of the science of metal cutting is the solution of practical problems associated with the efficient and precise removal of metal from work piece. It has been recognized that the reliable quantitative predictions of the various technological performance measures, preferably in the form of equations, are essential to develop optimization strategies for selecting cutting conditions in process planning. This paper summarizes an experimental study on the vibration damping based process strategies of surface finish enhancement presented in CNC milling operations. The paper considers the relation of surface finish to manufacturing industries in general and vibration as a factor that most influences quality of machined surfaces. The experimental and numerical analysis presented in this work provides an evaluation of various passive/active damping strategies to control vibrations during milling operations. The success of these methods is judged on their ability to decrease chatter, increase stability and ultimately deliver the surface quality demanded by my customer. The results of the study provide important resources for machining engineers in Academia and Industry, to improve surface finish by optimizing CNC milling processes. In this thesis experiments will be conducted to improve the surface finish quality of aluminum alloy work piece by using carbide tips. The type is bull nose tip. A series of experiments will be done by varying the milling parameters spindle speed, feed rate and depth of cut. The spindle speeds are 3500rpm, 3000rpm and 2000rpm. The feed rates are 200mm/min, 300mm/min and 400mm/min. Depth of cut is 0.2mm and 0.3mm and 0.4mm. Taguchi method is used to study the effect of process parameters and establish correlation among the cutting speed, feed and depth of cut with respect to the major machinability factor, surface finish. Validations of the modeled equations are proved to be well within the agreement with the experimental data.