Machining of thermoplastic material poses several challenges due to its low melting temperature and high thermal expansion which directly related to cutting force. Thus, controlling the cutting force and temperature is desirable for machining polyetheretherketone (PEEK). The cutting force is dependent on friction and shearing action produced by the tool. It is indicated the cutting force is significantly affected by tool cutter geometry. This paper aims to control the cutting force by optimizing the cutter geometries especially rake, clearance and helix angle on machining PEEK. The two –flutes of solid carbide ball nose end mills were used to conduct the experiments and the cutting force acquired was measured using piezoelectric dynamometer. Response Surface Methodology (RSM) approach was applied to design and analyse the optimal combination of tool geometry feature for machining PEEK. Based on obtained results, the best optimal values of tool geometry which contribute to minimum of cutting force were 17° rake angle, 26° of helix angle and 10° of clearance angle. The best control of tool geometry ultimately improves the cutting performance and reduces defect caused by high cutting forces.
Studies in urea granulation process using Top Spray Fluidized Bed Granulator (TSFBG) is still limited and requires in-depth research about the effectiveness and influence of droplets to the formation of urea granule (UG). Rate and time interval of spraying technique (Pulse) significantly influence the physical properties of urea granules. Cassava starch dissolves in water was selected as the binder released at various time interval to observe impact of spray droplet on UG size formation. Using Taguchi Method, the study had identified three leading factors contributed to the formation of droplet size namely volume of binder (VOB), time pulse of spraying (TPS) and spraying rate (SR). These factors were then evaluated in terms of the influence on response as signal-to-noise analysis (S/N ratios) from Taguchi to validate UG size in range 2 mm to 4 mm from screening process with respect to the actual experimental data. These results were useful for future experiment reference to determine pressure drop and surface contact during interaction between droplet and urea powder particles using TSFBG to obtain uniform UG size and smooth surface layer with reasonable hardness.
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