Investigation of cutting forces and surface roughness in face milling (down milling) operation on AlSiC MMC with HSS Tool

Abstract

This thesis investigates the cutting forces and surface roughness in the face milling operation on AlSiC Metal Matrix Composite (MMC) using an HSS tool. The effects of cutting parameters (cutting speed, feed rate, and depth of cut) on cutting forces and surface roughness are examined. The experiments are conducted on a horizontal milling machine with an HSS side and face milling cutter. Unlike traditional choices such as carbide or PCD tools, HSS tools, which are primarily designed for machining metals and alloys, are utilized in this study. In this experiment, force measurement is done by Kistler tool dynamometer and surface roughness is measured using a stylustype profilometer called Talysurf. The results show that increasing cutting speed initially leads to an increase in cutting forces, but after a certain point, the forces start to decrease due to reduced toolworkpiece interaction and workpiece softening caused by elevated temperatures. Higher feed rates and depth of cut result in increased cutting forces. Regarding surface roughness, an increase in cutting speed generally results in decreased roughness, indicating a smoother surface finish. However, an increase in feed rate and depth of cut shows an inverse relationship with surface roughness, leading to increased roughness values. The findings emphasize the importance of selecting appropriate cutting parameters to optimize cutting forces and surface roughness in face milling of AlSiC MMC. The use of HSS tools provides insights into their performance in machining MMCs. Future research can explore advanced tool materials or coatings to further improve the machining process and surface quality of AlSiC MMC