UNIVERSITY INSTITUTE OF ENGINEERING AND TECHNOLOGY, CSJM UNIVERSITY, KANPUR DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the Seminar entitled OPTIMIZATION OF MILLING OPERATION BY OPTIMIZING TOOL LIFE, FOLLOWING DOE APPROACH has been submitted by Group Number 2nd under my guidance in partial fulfillment of the degree of Bachelor of Technology in MECHANICAL ENGINEERING from UNIVERSITY INSTITUTE OF ENGINEERING AND TECHNOLOGY CSJM UNIVERSITY KANPUR during the academic year 2012-13.

DATE: PLACE: KANPUR

PROJECT GUIDE Lect. Yastuti Rao

HEAD OF THE DEPARTMENT Prof. Ramendra Singh Niranjan

ACKNOWLEDGEMENT

We convey our deep sense of gratitude to our supervisor Lect. Yastuti Rao, Department of Mechanical Engineering, University Institute Of Engineering And Technology, Kanpur University, Kanpur. It was due to their able efforts and dedication that we are able to complete our B-Tech project successfully. They have been instrumental in directing the work in the most systematic and desired manner.

We are thankful to Prof.Ramendra Singh Niranjan, Head of Mechanical Engineering, for their valuable support.

We are also thankful to Mr. Praveen Bhai Patel Sir (Workshop superintendent) and Mr. S.P. Singh Sir for their best efforts towards accomplishment of our goals.

We take this opportunity to express our deep sense of gratitude towards those, who have helped us in various ways, for preparing our project. At the last but not least, We are thankful to our parents, who had encouraged & inspired us with their blessings.

DATE: PLACE: KANPUR

JATIN PRAKASH NAIK LOKENDRA SINGH

[29259] [29317]

PRADEEP KUMAR KABIR [29271] SHAILY SRIVASTAVA SHIVAM SINGH [29270] [29283]

VIJAY KUMAR RAJBHAR [29296]

II

CONTENTS

CERTIFICATES ACKNOWLEDGEMENT CONTENTS FIGURE INDEX TABLE INDEX ABSTRACT

I II III-IV V VI VII

CHAPTER 1
1.1 1.2 1.3 1.4

INTRODUCTION
PROJECT BACKGROUND PROBLEM STATEMENT PROJECT OBJECTIVE PROJECT SCOPE

1-4
1 2 3 3

CHAPTER 2
2.1 2.1.1 2.1.2

LITERATURE REVIEW
MILLING MILLING MACHINES MECHANISM OF MILLING

4-26
4-5 6-8 9-11

2.2 2.2.1 2.2.2 2.2.3

CEMENTED CARBIDES HISTORY COMPOSITION SINTERING

12-20 12-13 14-15 15-20

III

2.3 2.3.1 2.3.2

TOOL WEAR TYPES OF TOOL WEAR TOOL LIFE

21-26 21-25 26-26

CHAPTER 3
3.1 3.2 3.3 3.4 3.5 3.6

METHODOLOGY
EXPERIMENTAL APPROACH DESIGN OF EXPERIMENT APPROACH EXPERIMENTAL SET UP METHODOLOGY FLOW CHART EXPERIMENTAL PROCEDURE CALCULATIONS

27-35
27 28 28 29 30-32 33-35

CHAPTER

RESULT COMPARISIONS

36-38

4.1

GRAPHS

37-38

CONCLUSION & REMARKS REFRENCES

39 40

IV

FIGURE INDEX
1. FIG 1.1 Diagram of revolution ridges 2. FIG 2.1 VERTICAL MILLING MACHINE 3. FIG 2.2 HORIZONTAL MILLING MACHINE 4. FIG 2.3 UNIVERSAL MILLING MACHINE 5. FIG 2.4 UP MILLING 6. FIG 2.5 DOWN MILLING 7. FIG 2.6 FLANK WEAR 8. FIG 2.7 CRATER WEAR 9. FIG 2.8 ABRASION WEAR 10. FIG 2.9 ADHESION WEAR 11. FIG 2.10 DIFFUSION WEAR 12. FIG 2.11 OXIDATION WEAR 13. FIG 3.1 ORIGINAL TOOL 14. FIG 3.2 HMT FN1U MILLING MACHINE 15. FIG 3.3 TOOL, WORKPIECE ARRANGEMENT 16. FIG 3.4 CONDUCTING EXPERIMENTS 17. FIG 3.5 TOOL DURING OPERATION 18. FIG 4.1 GRAPHS
5 6 7 8 9 10 21 22 23 23 24 24 30 31 31 31 32 37-38

TABLE INDEX
1. TABLE 3.1 2. TABLE 3.2 3. TABLE 4.1 4. TABLE 4.2 30 32 36 36

DATASHEET OF CALCULATED VALUES BETWEEN PAGE 36 & 37

VI

ABSTRACT
This project is about Optimization of Tool Life and hence optimizing the cost of milling operation. The objective of the project is to obtain an optimal setting of milling process parameters cutting speed, feed and depth of cut, which may result in optimizing tool life of Titanium aluminium nitride coated carbide mills while milling high carbon steel work piece(1% C, 0.3-0.7 % M n, 1-1.5 % Cr, 0.1-0.3 % Si). Data is collected from HMT FN1U universal milling machine. The machine was run by 3 samples of experiments. The experiment was conducted in dry conditions. DOE approach has been used for the conduction of experiment and it has been proved that it is better to use DOE approach than the conventional engineering judgement approach in order to optimize the tool life. The inputs of the model consist of feed, cutting speed and depth of cut while the output from the model is tool life and optimized cost per piece. The model is validated through a comparison of the experimental values with their theoretical counterparts. The direct and interaction effect of the machining parameter with tool wear were analyzed and plotted, which helped to select process parameter in order to reduce tool wear which ensures quality of milling. It is shown that the tool wear in end milling increases with the increase in feed, radial depths of cut and cutting velocity. The speed effect is dominant followed by the feed and the axial depth of cut.

VII