(Luận văn thạc sĩ) research and fabrication the effect of rough groove damping compliance on the surface roughness of straight milled part

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS MECHANICAL ENGINEERING TECHONOLOGY h RESEARCH AND FABRICATION THE EFFECT OF ROUGH GROOVE DAMPING COMPLIANCE ON THE SURFACE ROUGHNE SS OF STRAIGHT MILLED PART ADVISOR: ME NGUYEN TRONG HIEU STUDENT: BUI ANH KHOA HUYNH NGOC QUOC HUY LE DUY NHAN SKL 0 9 Ho Chi Minh City, Febuary, 2023 HCMC UNIVERCITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS h RESEARCH AND FABRICATION THE EFFECT OF ROUGH GROOVE DAMPING COMPLIANCE ON THE SURFACE ROUGHNESS OF STRAIGHT MILLED PART STUDENTS’ NAME & ID: Bui Anh Khoa – 18144029 Huynh Ngoc Quoc Huy – 18144021 Le Duy Nhan – 18144040 ADVISOR: ME Nguyen Trong Hieu HCM City, February, 2023 HCMC UNIVERCITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS h RESEARCH AND FABRICATION THE EFFECT OF ROUGH GROOVE DAMPING COMPLIANCE ON THE SURFACE ROUGHNESS OF STRAIGHT MILLED PART STUDENTS’ NAME & ID: Bui Anh Khoa – 18144029 Huynh Ngoc Quoc Huy – 18144021 Le Duy Nhan – 18144040 ADVISOR: ME Nguyen Trong Hieu HCM City, February, 2023 TABLE OF CONTENTS LIST OF FIGURES vi PREFACE xviii ABSTRACT xix Chapter 1: OVERVIEW The urgency of the topic Published domestic and foreign research results Goal of the topic Tasks and range of the project Tasks of the project Range of the project Research methods Chapter 2: THEORETICAL BASIS Theoretical foundations of metal cutting h Characteristics and role of metal cutting The basic movements of tool when cutting Feed movement and feed amount Extra movement and depth of cut Theoretical foundations of milling technology Overview of milling processing methods Type of milling tools Milling technology capabilities 11 Surface roughness of machined parts 12 Concepts 12 Effect of surface roughness 13 Evaluation criteria 15 Symbols and callouts for surface roughness on drawings 19 Surface roughness selection 23 Factors for surface roughness 23 Method of achieving surface roughness 24 Method of evaluating surface roughness 24 Vibration during cutting 24 Overview of vibration in cutting 24 Types and causes of vibration 24 Solution to vibration reduction 27 Making built-in damping system for cutting tool 28 Introduction to damping cutting tool 28 Milling technology with dampers cutter handle 35 Milling technology with dampers cutter handle 37 Optimization method 45 Taguchi method 45 ANN_GA method 47 Chapter 3: EMPIRICAL STUDY OF THE EFFECT OF DAMPINGING CUTTER HANDLES ON DETAILED SURFACE GLOSS 49 Experiment conditions 49 h Cutting conditions 49 Length of cutter 50 CNC machine VM750 51 Experiment procedure 51 Investigate the influence of L on the surface gloss of the workpiece: 51 Investigate the influence of l on the surface gloss of the workpiece: 52 Investigate the influence of ∅ on the surface gloss of the workpiece: 53 Investigate the influence of 𝐑 on the surface gloss of the workpiece: 54 Investigate the influence of 𝐝 on the surface gloss of the workpiece: 54 Investigate the influence of 𝐡 on the surface gloss of the workpiece: 55 Damping cutting tools and damping cores 56 Workpieces 58 Measuring instrument 59 Cases for experimentation 61 Experiments process and Results 64 Measuring and comparing surface roughness results 64 Optimization method 72 Chapter 4: CONCLUSION AND FURTHER RESEARCH DIRECTION 83 Conclusion 83 Further research direction 83 REFERENCES 84 h LIST OF FIGURES h Figure 2.1: Technology system [7] Figure 2.2: Basic movement of tool when milling [7] Figure 2.3: Reverse milling [8] Figure 2.4: Forward milling [8] Figure 2.5: Cylindrical milling cutter [9] 10 Figure 2.6: Angle milling cutter [9] 10 Figure 2.7: Disc milling cutter [9] 10 Figure 2.8: End milling cutter [9] 11 Figure 2.9: Milling process capabilities [9] 12 Figure 2.10: Types of undulations on the detailed surface [10] 13 Figure 2.11: Effect on wear resistance [10] 14 Figure 2.12: Effect on fatigue strength of parts [10] 14 Figure 2.13: Effect on corrosion resistance [10] 15 Figure 2.14: Effect on corrosion resistance 15 Figure 2.15: Surface profile [10] 16 Figure 2.16: Surface profile [10] 17 Figure 2.17: Surface roughness note definitions (EN ISO 1302) [11] 19 Figure 2.18: How to read the requirements for surface texture [11] 20 Figure 2.19: Surface texturing on contour lines representing surfaces [11] 21 Figure 2.20: Feature-of-size dimension – surface texture requirement [11] 21 Figure 2.21: Geometrical tolerances indication [11] 22 Figure 2.22: Extensions lines of cyclindrical features [11] 22 Figure 2.23: Cyclindrical and prismatics surfaces [11] 23 Figure 2.24: Damping cutting tools [11] 28 Figure 2.25: Damping cutting tool structure 29 Figure 2.26: Vibration between normal cutter and damping cutter 29 Figure 2.27: Damping cutter [20] 31 Figure 2.28: The parameters of the damper cutter [20] 32 Figure 2.29: General technique [20] 32 Figure 2.30: Life force parts [20] 33 Figure 2.31: Aviation sector [20] 33 Figure 2.32: Oil and gas [20] 34 Figure 2.33: Auto parts [20] 34 Figure 2.34: Problems when machining [20] 35 Figure 2.35: Reduce vibrations when machined with damping cutter [20] 36 Figure 2.36: damping effect when using extensions chart [20] 36 Figure 3.1: Recommended cutting condition of inserts 50 Figure 3.2: Length of tool holder and cutter 50 h Figure 3.3: CNC machine VM750 51 Figure 3.4: Definitions for parameters of damping compliance 52 Figure 3.5: Definitions for parameters of damping compliance 52 Figure 3.6: Definitions for parameters of damping compliance 53 Figure 3.7: Definitions for parameters of damping compliance 54 Figure 3.8: Definitions for parameters of damping compliance 54 Figure 3.9: Definitions for parameters of damping compliance 55 Figure 3.10: Damping cutting tool 56 Figure 3.11: Insert APMT1135PDER parameters 57 Figure 3.12: Damping compliance 58 Figure 3.13: Custom damping compliance holder 58 Figure 3.14: Damping cutting tool assembly 58 Figure 3.15: Experiment samples 59 Figure 3.16: Mitutoyo SJ-201 roughness meter 60 Figure 3.17: Mitutoyo SJ-201 roughness meter [19] 61 Figure 3.18: Definitions for parameters of damping compliance 62 Figure 3.19: Measuring Ra value 64 Figure 3.20: Results after measuring 65 Figure 3.21: Comparision of normal tool and damping compliance to 67 Figure 3.22: Comparision of normal tool and damping compliance to 68 Figure 3.23: Comparision of normal tool and damping compliance to 12 69 Figure 3.24: Comparision of normal tool and damping compliance to 12 70 Figure 3.25: Comparision of normal tool and damping compliance 17 to 20 71 Figure 3.26: Comparision of normal tool and damping compliance 21 to 25 72 Figure 3.27: Analyze Taguchi Design 72 Figure 3.28: Choosing factors 73 Figure 3.29: Choosing response data 74 Figure 3.30: Main effect for means 74 Figure 3.31: Input and target variables 75 Figure 3.32: Neural Network/Data Manager 76 Figure 3.33: Import Input Data 76 Figure 3.34: Import Target Data 77 Figure 3.35: Create new neural network 77 Figure 3.36: Prepare data and function for new neural network 78 Figure 3.37: Training network 79 Figure 3.38: Neural network training regression 80 Figure 3.39: Fitness function code 80 Figure 3.40: Optimization setup in Mathlab 81 Figure 3.41: ANN_GA method results 81 Figure 3.42: Definitions for parameters of damping compliance 81 Figure 3.43: Comparison surface roughness of optimal damping tool and normal tool 82 h h LIST OF TABLES Table 2.1: Surface roughness parameter values (ISO 12085:1996) [10] 18 Table 2.2: Standard values of Ra and Rz [10] 19 Table 2.3: Surface roughness value according to the dimensional accuracy grade [10] 23 Table 3.1: Experiments conditions 49 Table 3.2: Parameters of damping compliance when changing L variable value 52 Table 3.3: Parameters of damping compliance when changing l variable value 53 Table 3.4: Parameters of compliance when changing Ø variable value 53 Table 3.5: Parameters of compliance when changing R variable value 54 Table 3.6: Parameters of compliance when changing d variable value 55 Table 3.7: Parameters of compliance when changing h variable value 55 Table 3.8: Basic component of high-speed steel [18] 56 Table 3.9: High-speed steel heat treatment [18] 56 Table 3.10: Chemical compositions and mechanical properties of SS400 steel 59 Table 3.11: All damping cases dimensions 63 Table 3.12: Surface roughness for each cases 65 Table 3.13: Average surface roughness of normal cuttin tool 66 Table 3.14: Parameters and surface roughness of compliance to 66 Table 3.15: Parameters and surface roughness of compliance to 67 Table 3.16: Parameters and surface roughness of compliance to 12 68 Table 3.17: Parameters and surface roughness of compliance 13 to 16 69 Table 3.18: Parameters and surface roughness of compliance 13 to 16 70 Table 3.19: Parameters and surface roughness of compliance 13 to 16 71 Table 3.20: Parameters of optimized damping cutting tool 82 Table 3.21: Surface roughness of optimized damping tool and normal tool 82 3.2 0.8 1.5 0.006 R1.75 0.006 0.036 0.1 h M6 1x45 15 25 0.052 70 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 15 Steel T l :2:1 S t :1 3.2 0.8 1.5 R1.5 0.006 0.006 0.036 0.1 h M6 1x45 15 25 0.052 70 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 16 Steel T l :2:1 S t :1 3.2 0.8 0.006 R2 0.006 0.036 0.1 M6 1x45 25 0.052 h 15 70 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 17 Steel T l :2:1 S t :1 3.2 0.8 15 1.75 25 0.006 0.052 R2 0.006 h M6 1x45 70 0.036 0.1 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 18 Steel T l :2:1 S t :1 3.2 0.8 1.25 25 0.052 0.006 h 15 R2 0.006 M6 1x45 70 0.036 0.1 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 19 Steel T l :2:1 S t :1 3.2 0.8 0.006 15 25 0.052 R2 0.006 h M6 1x45 70 0.036 0.1 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 20 Steel T l :2:1 S t :1 3.2 0.8 1.5 0.006 R2 0.006 0.036 0.1 h M6 1x45 15 25 0.052 14 70 0.18 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 21 Steel T l :2:1 S t :1 3.2 0.8 1.5 0.006 R2 0.006 0.036 0.1 h M6 1x45 15 25 0.052 11 70 0.18 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 22 Steel T l :2:1 S t :1 3.2 M6 0.8 1.5 0.006 15 25 0.052 R2 0.006 h 1x45 70 0.036 0.1 0.15 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 23 Steel T l :2:1 S t :1 3.2 0.8 1.5 0.006 R2 0.006 0.036 0.1 M6 1x45 25 0.052 h 15 70 0.1 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 24 Steel T l :2:1 S t :1 3.2 0.8 1.5 0.006 R2 0.006 0.036 h M6 1x45 15 25 0.052 70 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m Tra Tr ng H S Ph m k Thu t TP.HCM Khoa: L p: Compliant 25 Steel T l :2:1 S t :1 3.2 0.8 15 1.75 0.006 15 0.043 R2 0.006 0.036 3 h M6 1x45 0.1 0.1 60 0.074 Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m tra Tr ng Khoa L p Compliant 26 H S ph m K thu t tp.HCM Steel T l :2:1 S l ng : 3.2 0.8 1x45 +0 1.5 - 0.003 +0.002 R1.5 - 0.036 M6 +0.58 25 - h 15 +0.656 65 - Y u c u k thu t: Dung sai tr kh ng v t qu 0.05mm o m t u kh ng v t qu 0.05 tr n to n b chi u d i Ng iv Ki m tra Tr ng Khoa L p Compliant 27 H S ph m K thu t tp.HCM Steel T l :2:1 S l ng : R1 ,5 0,5x45 M6 1,5 h 20 25 85 Ng iv Ki m tra Tr ng Khoa L p Compliant 27 H S ph m K thu t tp.HCM Steel T l :2:1 S l ng : h S K L 0