Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdge Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdgeTM Softwa

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Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T,

4T for Surface-Rough Machining by Third Wave AdvantEdge

TM

Software Simulation.

A Graduation Project Report submitted by

Dony Irvan Siswanto

9999156136/D200122001

In fulfillment of the requirement of

One-year course in Mechanical Engineering Department,

Wuxi Institute of Technology

a part of Undergraduate study in the Department of Mechanical Engineering,

Universitas Muhammadiyah Surakarta

Towards the degree of

Bachelor of Engineering (Mechanical)

MECHANICAL ENGINEERING DEPARTMENT

WUXI INSTITUTE OF TECHNOLOGY

WUXI JIANGSU PROVINCE P.R. CHINA

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FOREWORD

Thanks to Allah SWT who gives his-mercy and blessing, so author can

finish this report of Graduation Project with the planed time. Blessings and

greetings may keep to our Prophet Muhammad SAW and all his family and

friends in enforcing Dinullah on this earth.

This report is written to finish of my undergraduate study in mechanical

Engineering department of Universitas Muhammadiyah Surakarta.

In writing this report, of course, many people who have provided support

both morally and materially. Therefore, the authors would like to express

gratitude boundless to:

1. Tri Widodo Besar Riyadi, ST., M.Sc., Ph.D as the head of

Mechanical Engineering Department Universitas Muhammadiyah

Surakarta.

2. Mr. Zhang Zheng, M.Eng. as the head of Mechanical Engineering

Department Wuxi Institute of Technology.

3. Dwi Agus Anggono,ST., M.Eng., Ph.Das my supervisor lecturers.

4. Jack and May as my first Chinese friend who always help me to

study Chinese language.

5. And all of my friends and also my family.

Finally, the author hopes this report is useful for everyone that read it.

Wuxi Jiangsu, March 2016

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ABSTRACT

Surface rough-machining is one of the important process before finishing process. For the finding the best result of rough-machining’s quality criteria, least machining time and least remaining volume without making worse of tool wear after roughing so need detection and analysis

optimum parameter proses without ignoring tool wear’s aspect. Cemented

Carbide flat End-mill with 2, 3, 4 Flutes used as the main case parameter study with Al 7075 T6 as the workpiece materials, by calculation and bring it to Third Wave Advant EdgeTM Systems Software simulation some data become recommendation production parameters as the final conclusion.

Key words: Rough-machining, Cemented Carbide End-mill, Al 7075

T6, Third Wave Advant EdgeTM.

ABSTRAK

Proses kekasaran permukaan merupakan salah satu proses penting

sebelum proses finishing. Untuk menemukan hasil terbaik dari kriteria

kualitas kasar-mesin ini, waktu mesin setidaknya dan volume tersisa

sedikit tanpa membuat lebih buruk memakai alat setelah hidup seadanya

sehingga perlu deteksi dan analisis optimum Proses parameter tanpa

mengabaikan aspek memakai alat ini. Semen Carbide datar End-pabrik

dengan 2, 3, 4 Flutes digunakan sebagai studi parameter kasus utama

dengan Al 7075 T6 sebagai bahan benda kerja, dengan perhitungan dan

membawanya ke simulasi Gelombang Ketiga Advant EdgeTM Sistem

Software beberapa data menjadi parameter produksi rekomendasi sebagai

kesimpulan akhir.

Kata kunci: proses kekasaran permukaan, Karbida Endmill, Al 7075

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LIST OF PICTURE

Figure 1. Down milling with their parameter. ... 6

Figure 2. The variety of end mill cutting tools types. ... 13

Figure 3. End mill attributes and terminology, (a). End mill view, (b). Cross section view, (c). Side view [33]. ... 14

Figure 4. (A). Microstructure of WC-Co tool substrate (10000X BSE Image) and (B). EDS of area with Elemental composition ... 15

Figure 5. The 3D modeling of flat end-mills that use before simulation with (a).2-flutes, (b). 3-flutes and (c). 4-flutes are done by NX 9.1. ... 17

Figure 6. Statistical Variability Modeling of AdvantEdge 7.1 TM. ... 19

Figure 7. AdvantEdge FEM temperature presentation [39]. ... 19

Figure 8. Speciment of workpiece material Al-7075 T6... 22

Figure 9. Flat End-mill ø8 3T (a). Tool-length view. (b). Flutes view. ... 22

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LIST OF TABLE

Table 1.1 General equation of milling process [18]. ... 7

Table 1.2 Physical properties of Al-7075 T6[29]. ... 11

Table 3. Tools Specification of 3D Modeling. ... 23

Table 4. Initial data parameters. ... 24

Table 5. Intial inputing data to TWS-Pluge simulation. ... 25

Table 6. Table of Continuous Feedrate Schema. ... 25

Table 7. Continuous DOC Data Schema ... 26

Table 8. Continuous Changing-Parameter. ... 27

Table 9. result of Initial data parameter calculation. ... 28

Table 10. Interpolation to find feed rate value. ... 29

Table 11. Interpolation to find depth of cut. ... 31

Graph 1.Prediction result of Experiment-simulation 1. ... 29

Graph 2. Prediction result of Experiment-simulation 2. ... 30

Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdge Detection and Analysis Tool Wear of Carbide Flat End Mills 2T, 3T, 4T for Surface-Rough Machining by Third Wave AdvantEdgeTM Softwa