Publication: The effect of pocket milling cutting parameters on cutting forces, total deformation and surface quality of aluminum 6061-t6
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Date
2024-07-01
Authors
Muhammad Al Amien, Hamzah
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Abstract
VAT Manufacturing Malaysia Sdn Bhd is an industry specialize in milling vacuum valves production. The quality of vacuum valve needs to be in high accuracy and quality as it is important to preserve the vacuum environment during the transfer process of manufacturing semiconductor wafer. One of VAT products, vacuum valve body experienced deflections resulting its length exceeding the allowable range of length for the product resulted in poor quality of vacuum valve body produced. Hence, it is important to find which milling processes produced high cutting forces during machining and identify which machining parameters is influencing the most in product quality for future improvement. It is found that, the highest cutting force produced during the production of the vacuum valve body is during pocket milling. The study presents an experimental pocket milling towards Aluminium 6061-T6 in a vertical computer numerical control (CNC) machine. The criteria for high-quality machining products are the workpiece dimension accuracy and surface roughness. Taguchi method was applied as Design of Experiment (DOE) to optimize the machining parameters during machining. Besides, this research is also to study the relationship between machining parameters towards cutting forces, surface roughness and total deformation of the machining product and generate linear regression model for total deformation occurring during machining. Spindle speed at 5500, 5000 and 4500 rpm, feed rate at 500, 700 and 900 mm/min and depth of cut at 0.5, 1.0 and 1.5 mm were the parameters used to optimize machining process in this study. Highest cutting forces obtained for the study are 172.70N, 197.30 N and 138.39 N in X, Y and Z axis respectively. Besides, the highest surface roughness obtained for the study is 0.3405 µm. The study found that smoother surface was obtained at lower radial cutting forces. Besides, lower deformation of the workpiece was found at lower radial cutting forces also. Thus, lower surface roughness and lower total deformation of the machined workpiece can be achieved at lower radial cutting forces. Lower radial cutting forces were observed at higher spindle speed and at lower depth of cut and feed rate. The optimum machining parameters for the study was at spindle speed 5500 rpm, 500 mm/min of feed rate and 0.5 mm of depth of cut. From linear regression model, the deformation regression equation was obtained which predict the deformation that will
occur during machining at different value of machining parameters.