Impact of Machining Parameters on the Surface Roughness of Machined PU Block
Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
[1] D. K. Back, T. J. Ko, H. S. Ko and H. S. Kim, “A Dynamic surface
roughness model for face milling,” Precision Engineering, vol. 20, 1997,
pp. 171-178.
[2] S. Neseli, S. Yaldiz and E. Turkes, “Optimization of Tool Geometry
parameters for turning operations based on the response surface
methodology,” Journal of Measurement, vol. 44(3), 2011, pp. 580-587.
[3] K. Popov, S. Dimov, A. vanov, D. T. Pham and E. Gandarias, “New
tool-workpiece setting up technology for micro-milling,” International
Journal of Advanced Manufacturing Technology, vol.47, 2010 pp. 21-
27.
[4] Y. Yung-Kuang, C. Ming-Tsam and L. Show-Shyan, “Optimization of
dry machining parameters for high-purity graphite in end milling process
via design of experiments methods,” Journal of Materials Processing
Technology, vol. 209, 2009, pp. 4395-4400.
[5] F. Kuang-Hua and W. Chin-Fu, “A proposed statistical model for
surface quality prediction in end milling of Al alloy,” International
Journal of Machine Tools & Manufacture, vol. 35, 1995, pp. 1187-1200.
[6] S. Thamizhmanii, S. Sarapudin and S.Hasan, “Analysis of surface
roughness by using Taguchi method,” Journal of Achievements in
Materials and Manufacturing Engineering, vol. 20 (1-20), 2007, pp.
503-505.
[7] C. S. M. Son, H. S. Lim and J. H. Ahn, “Effects of the friction coefficient
on the minimum cutting thickness in micro cutting,”
International Journal of Machine Tools and Manufacture, vol. 45, 2005,
pp. 529-535.
[8] M. Alauddin, M. A. ElBaradie and M. S. J. Hashmi, “Prediction of tool
life in end milling by response surface methodology,” Journal of
Materials Processing Technology, vol. 71, 1997, pp. 456-465.
[9] M. Hasegawa, A. Seireg and R.A. Lindberg, “Surface roughness model
for turning,” Tribology International, vol. 2, 285–289. December 1976.
[10] O. B. Abouelatta and J. M´adl, “Surface roughness prediction based on
cutting parameters and tool vibrations in turning operations,” Journal of
Materials Processing Technology, vol. 118, 2001, pp. 269–277.
[11] E. Erisken, “Influence from production parameters on the surface
roughness of a machine short fibre reinforced thermoplastic,”
International Journal of Machine Tools and Manufacture, vol. 39 (10),
1999, pp. 1611–1618.
[12] Y. Su, N. He, L. Li and X. L. Li, “An experimental investigation of
effects of cooling/lubrication conditions on tool wear in high speed end
milling of Ti-6Al-4V,” Journal of Wear, vol. 261, 2006, pp. 760-766.
[13] Z. Y. Wang and K. P. Rajurkar, “Cryogenic machining of hard-to- cut
materials,” Journal of Wear, vol. 239, 2000, pp. 168–175.
[14] Y. S. Hong and Y. C. Ding, “Cooling approaches and cutting
temperatures in cryogenic machining of Ti-6Al-4V”, International
Journal of Machine Tools and Manufacture, vol. 4, 2001, pp. 1417–
1437.
[15] B. Yalçın, A. E. Özgür and M. Koru, “The effects of various cooling
strategies on surface roughness and tool wear during soft materials
milling”, Journal of Materials and Design, vol. 30, 2009, pp. 896–89.
[16] D. Dingley, “Progressive Steps in the Development of Electron
Backscatter Diffraction and Orientation Imaging Microscopy,” Journal
of Microscopy, vol. 213 (3), 2004, pp. 214-224.
[17] S. Thomas, S. Turner and M. Jackson, “Microstructural Damage during
High-speed Milling of Titanium Alloys”, Journal of Scripta Materialia,
vol. 62, 2010, pp. 250-253.
[18] A. Yamamoto, T. Yamada, S. Nakhigashi, L. Liu, M. Teresawa and H.
Tsubakino, “Effects of surface grinding on hardness distribution and
residual stress in Low carbon austentic stainless steel SUS316l” Journal
of Iron and Steel Institute of Japan International, vol. 44 (10), 2004, pp.
1780-1782.
[19] S. To, W. B.Lee and C. F. Cheung, “Orientation Changes of Aluminium
Single Crystals in Ultra-precision Diamond Turning,” Journal of
Materials Processing Technology, vol. 140 (1-3), 2003, pp. 346-351.
[20] S. Thamizhmanii, S. Sarapudin and S. Hasan, “Analysis of surface
roughness by using Taguchi method”, Journal of Achievements in
Materials and Manufacturing Engineering, vol. 20 (1-20), 2007, pp.
503-505.
[1] D. K. Back, T. J. Ko, H. S. Ko and H. S. Kim, “A Dynamic surface
roughness model for face milling,” Precision Engineering, vol. 20, 1997,
pp. 171-178.
[2] S. Neseli, S. Yaldiz and E. Turkes, “Optimization of Tool Geometry
parameters for turning operations based on the response surface
methodology,” Journal of Measurement, vol. 44(3), 2011, pp. 580-587.
[3] K. Popov, S. Dimov, A. vanov, D. T. Pham and E. Gandarias, “New
tool-workpiece setting up technology for micro-milling,” International
Journal of Advanced Manufacturing Technology, vol.47, 2010 pp. 21-
27.
[4] Y. Yung-Kuang, C. Ming-Tsam and L. Show-Shyan, “Optimization of
dry machining parameters for high-purity graphite in end milling process
via design of experiments methods,” Journal of Materials Processing
Technology, vol. 209, 2009, pp. 4395-4400.
[5] F. Kuang-Hua and W. Chin-Fu, “A proposed statistical model for
surface quality prediction in end milling of Al alloy,” International
Journal of Machine Tools & Manufacture, vol. 35, 1995, pp. 1187-1200.
[6] S. Thamizhmanii, S. Sarapudin and S.Hasan, “Analysis of surface
roughness by using Taguchi method,” Journal of Achievements in
Materials and Manufacturing Engineering, vol. 20 (1-20), 2007, pp.
503-505.
[7] C. S. M. Son, H. S. Lim and J. H. Ahn, “Effects of the friction coefficient
on the minimum cutting thickness in micro cutting,”
International Journal of Machine Tools and Manufacture, vol. 45, 2005,
pp. 529-535.
[8] M. Alauddin, M. A. ElBaradie and M. S. J. Hashmi, “Prediction of tool
life in end milling by response surface methodology,” Journal of
Materials Processing Technology, vol. 71, 1997, pp. 456-465.
[9] M. Hasegawa, A. Seireg and R.A. Lindberg, “Surface roughness model
for turning,” Tribology International, vol. 2, 285–289. December 1976.
[10] O. B. Abouelatta and J. M´adl, “Surface roughness prediction based on
cutting parameters and tool vibrations in turning operations,” Journal of
Materials Processing Technology, vol. 118, 2001, pp. 269–277.
[11] E. Erisken, “Influence from production parameters on the surface
roughness of a machine short fibre reinforced thermoplastic,”
International Journal of Machine Tools and Manufacture, vol. 39 (10),
1999, pp. 1611–1618.
[12] Y. Su, N. He, L. Li and X. L. Li, “An experimental investigation of
effects of cooling/lubrication conditions on tool wear in high speed end
milling of Ti-6Al-4V,” Journal of Wear, vol. 261, 2006, pp. 760-766.
[13] Z. Y. Wang and K. P. Rajurkar, “Cryogenic machining of hard-to- cut
materials,” Journal of Wear, vol. 239, 2000, pp. 168–175.
[14] Y. S. Hong and Y. C. Ding, “Cooling approaches and cutting
temperatures in cryogenic machining of Ti-6Al-4V”, International
Journal of Machine Tools and Manufacture, vol. 4, 2001, pp. 1417–
1437.
[15] B. Yalçın, A. E. Özgür and M. Koru, “The effects of various cooling
strategies on surface roughness and tool wear during soft materials
milling”, Journal of Materials and Design, vol. 30, 2009, pp. 896–89.
[16] D. Dingley, “Progressive Steps in the Development of Electron
Backscatter Diffraction and Orientation Imaging Microscopy,” Journal
of Microscopy, vol. 213 (3), 2004, pp. 214-224.
[17] S. Thomas, S. Turner and M. Jackson, “Microstructural Damage during
High-speed Milling of Titanium Alloys”, Journal of Scripta Materialia,
vol. 62, 2010, pp. 250-253.
[18] A. Yamamoto, T. Yamada, S. Nakhigashi, L. Liu, M. Teresawa and H.
Tsubakino, “Effects of surface grinding on hardness distribution and
residual stress in Low carbon austentic stainless steel SUS316l” Journal
of Iron and Steel Institute of Japan International, vol. 44 (10), 2004, pp.
1780-1782.
[19] S. To, W. B.Lee and C. F. Cheung, “Orientation Changes of Aluminium
Single Crystals in Ultra-precision Diamond Turning,” Journal of
Materials Processing Technology, vol. 140 (1-3), 2003, pp. 346-351.
[20] S. Thamizhmanii, S. Sarapudin and S. Hasan, “Analysis of surface
roughness by using Taguchi method”, Journal of Achievements in
Materials and Manufacturing Engineering, vol. 20 (1-20), 2007, pp.
503-505.
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:68748", author = "Louis Denis Kevin Catherine and Raja Aziz Raja Ma’arof and Azrina Arshad and Sangeeth Suresh", title = "Impact of Machining Parameters on the Surface Roughness of Machined PU Block", abstract = "Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
", keywords = "Polyurethane (PU), design of experiment (DOE), scanning electron microscope (SEM), surface roughness.", volume = "8", number = "12", pages = "1476-6", }
