Evaluation of Aluminum Surface Roughness in the Slot End-Mill Process with Variable Helix Angle

Sonief, Achmad As’ad; Fauzan, Arda Nur; Alamsyah, Fikrul Akbar

doi:10.1088/1757-899x/494/1/012045

Cited by 4 publications

(4 citation statements)

References 8 publications

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“…Oleh karena itu, deteksi awal chatter secara tepat waktu sangat penting dan krusial dalam proses pemesinan. Ketika ketebalan chip melebihi batas tertentu, efek regeneratif ini menjadi dominan dan chatter berkembang, menghasilkan akhir permukaan yang buruk dan bergelombang [8] . Selain itu, metal working fluids (mwfs) lubricate juga dapat mengurangi efek gaya yang diberikan oleh pahat pada material di area cutting zone [9] .…”

Section: Pendahuluanunclassified

“…Cutting tool yang akan digunakan yaitu pahat end mill dengan sudut helix normal yaitu 30 0 dan variable helix adalah 36/38 0 (variabel) seperti pada gambar 1. Bentuk sudut pada pahat variabel ini akan memberikan perbadaan sudut pitch yang berbeda antara dua pahat end mill [8] . Spesimen yang telah disiapkan dipasang di mesin cnc kemudian dilanjutkan dengan proses zig-zag.…”

Section: Alat Dan Bahan Penelitianunclassified

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Pengaruh Pahat Endmill Normal Dan Variabel Helix Angle Pada Metode Pocket Zig-Zag Terhadap Chatter

Abriandika,

Sonief,

Irawan

2023

JRM

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The manufacturing industry mostly uses CNC Milling machines in processing products that require high precision values. This machine is capable of a wide variety of feeding methods, inclinations, feed speeds, various tool styles, and much more. The purpose of this research is to analyze one method of infeed direction with the Zig-Zag effect by using 2 types of normal and variable tool types combined with variations in spindle speed and DOC to find out which variable is effective and produce a smoother comparison of surface roughness values. The type of material tested was SS 304 because this material has good advantages against corrosion. From the results of research conducted on this material for the use of a variable tool, it has an average roughness value of 0.327 µm and for the results of the roughness test on the use of a normal tool, it has an average roughness value of 0.470 µm. From the results of this research, it can be concluded that the value of the Depth Of Cut (DOC), the roughness value are directly proportional, and the faster the spindle rotation, the frictional force generated also increases. The highest Ra value from the research results occurred in DOC 1.6 mm with a spindle speed of 2750 rpm using a variable tool of 0.361 µm and a roughness value of 0.516 µm on a normal tool. The conclusion of this research is that the variable tool produces a lower Ra value than the normal tool so that the type of material defects caused by chatter vibration can be reduced.

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Section: Pendahuluanunclassified

Section: Alat Dan Bahan Penelitianunclassified

Pengaruh Pahat Endmill Normal Dan Variabel Helix Angle Pada Metode Pocket Zig-Zag Terhadap Chatter

Abriandika,

Sonief,

Irawan

2023

JRM

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“…A milling experimental study was conducted by a researcher [21] to improve the surface unevenness of AISI 52100 bearing steel and the impact level of the workpiece. Te researcher [22] evaluated the surface roughness in the slot end-mill process with a variable helix angle for aluminium machining. A statistical analysis was conducted to measure surface roughness and proved that variable helix angles can produce much higher surface roughness quality than standard helix angle tools.…”

Section: Introductionmentioning

confidence: 99%

A Hybrid Nondominant-Based Genetic Algorithm (NSGA-II) for Multiobjective Optimization to Minimize Vibration Amplitude in the End Milling Process

Gopal,

Gutema,

Lemu

et al. 2024

Advances in Materials Science and Engineering

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Aluminium is a noncorrosive, lightweight material used to fabricate parts for the aerospace, automobile, and construction industries. Due to the low-temperature resistance, more heat is generated. At the same time, in machining, tremendous efforts are taken to keep friction and chatter to a minimum and to attain better quality and perfect output, and also more attention is required while selecting the machining process parameters. Spindle speed, rate of feed, radial and axial depth of cut, and radial rake angle of the tool are the parameters utilized to machine aluminium 6063 using the HSS tool on CNC milling to estimate spindle and worktable vibration using a prediction model. In this study, the design of the experiment of the response surface methodology approach is used to create a second-order statistical equation for experimentation with the Design-Expert v12 software. The performance characteristics are analyzed using the ANOVA method. The spindle speed achieved the lowest vibration between 2000 and 3000 rpm. Next, axial and radial depths were the most vibration-affecting parameter compared to the rate of feed and radial rake angle of the tool. To find the best feasible response, the nondominant sorting genetic algorithm II (NSGA II) approach was trained and tested using MATLAB software. Using a Pareto-optimal technique, the optimum worktable vibration ranged from 0.00284 to 0.00165 mm/s2, whereas the spindle vibration ranged from 0.02404 to 0.01336 mm/s2. The predicted values were found to be in an excellent argument when Pareto-optimal solutions are used.

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“…Varying helix angles with different angles on each flute will result in variations in the time lag. Interpreting this time lag can minimize regenerative chatter and avoid using the same frequency as the machine's natural frequency, so that resonance can be reduced [1]. The axial depth of cut and spindle speed play a significant role in the machining process [2].…”

Section: Introductionmentioning

confidence: 99%

Comparison of Chatter Control of Variable and Regular Helix Tools in the Aluminum End-Milling Process

Sonief

Ma'arif

Pratikto

et al. 2023

MECHTA

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In the chatter, machining operations are undesirable because of the phenomena that affect product results, machining accuracy, tool life, and high operating value. Chatter is a vibration phenomenon that occurs in cutting tools due to the self-excitation of the influence of cutting parameters during the operation process of the machine. Types of chatter in machinery are regenerative and resonant. Because the pitch angles of variable helix tools vary, the helix angles of variable tools produce different tooth passing frequencies on each tool eye next to each other and can be used to prevent and control resonance. This study aimed to compare chatter control from the variable helix and regular-angle tools in the aluminum end milling process. The method is carried out through the end milling process experiment to determine the chatter control of the variable helix and regular-angle tools through the stability loop diagram. The results from this study were obtained by comparing control chatters in the milling process through controlling variable and standard helix angles as a guideline to produce the best surface roughness in the end milling process made from aluminum. The comparison of estimated control charts from variable helix tools is more comprehensive than regular helix tools.

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Evaluation of Aluminum Surface Roughness in the Slot End-Mill Process with Variable Helix Angle

Cited by 4 publications

References 8 publications

Pengaruh Pahat Endmill Normal Dan Variabel Helix Angle Pada Metode Pocket Zig-Zag Terhadap Chatter

Pengaruh Pahat Endmill Normal Dan Variabel Helix Angle Pada Metode Pocket Zig-Zag Terhadap Chatter

A Hybrid Nondominant-Based Genetic Algorithm (NSGA-II) for Multiobjective Optimization to Minimize Vibration Amplitude in the End Milling Process

Comparison of Chatter Control of Variable and Regular Helix Tools in the Aluminum End-Milling Process

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