Experimental Investigation on the Effect of Presented By

Process Parameters in Trochoidal Milling B. OMKAR RA1411002010358

T. SWETHAN RA1411002010374
SCHOOL OF MECHANICAL ENGINEERING, SRM IST
PROJECT GUIDE – J. Santhakumar (Sr. G) D. BHARAT RA1411002010736
(Assistant Professor) M6 - Batch

Abstract Methodology Experimental Results

Inputs Outputs
The need for high quality and high productivity in Run
(rpm) (mm/min) (mm)
Fc
(N)
Es
()
Ra
(μm)
industries lead to a wave of revolution in the Introduction

machining technology and the result of that is the 1

2
1800
3200
150
150
0.4
0.4
68.20798371 0.909439783 0.72535
0.375425
Literature Review 58.64970524 0.78199607
development of high speed machining, in short 3
4
1800
3200
250
250
0.4
0.4
100.861569 0.806892552 0.654725
0.390475
70.28 0.56224
HSM, and the concept of tool path strategy. The tool Problem Statement
5
6
1800
3200
150
150
1
1
65.078 0.867706667 0.666654
0.324025
54.48495297 0.72646604
path strategy is a concept of manipulating the path 7
8
1800
3200
250
250
1
1
88.53473922 0.708277914 0.6708
0.44165
61.788 0.494304
of the tool in a way to achieve a desired No Tool Path Selection
9
10
1800
3200
200
200
0.7
0.7
76.98992151 0.769899215 0.65229
0.36689
55.73143775 0.557314378
characteristic while producing at a higher rate. 11
12
2500
2500
150
250
0.7
0.7
59.49 0.7932 0.527913
0.576775
80.024914 0.640199312
Although tool path strategy is a familiar concept in a Selection of Parameters 13
14
2500
2500
200
200
0.4
1
71.21469655 0.712146966 0.5225
0.526675
61.77884589 0.617788459
CAM procedure, the knowledge on the extent of its Yes 15
16
2500
2500
200
200
0.7
0.7
65.4884213 0.654884213 0.525
0.527533445
67.62760444 0.676276044
influence on the output characteristics of a product Finalizing 17
18
2500
2500
200
200
0.7
0.7
66.48657142 0.664865714 0.52349
0.536728
67.49356626 0.674935663
is only known to a limited extent. In mold or die 19
20
2500
2500
200
200
0.7
0.7
66.44923908 0.664492391 0.516208
0.523035
67.67785895 0.676778589
industry slots are made using HSM, where there is Simulation & Experiments

still a need for hand polishing there by extending the

Output Measurements
Optimized Results
cycle time resulting in decreased productivity. In
this study the influence of trochoidal tool path
strategy on output characteristics for a slot milling
Optimization & Validation
3D SURFACE PLOTS
operation on die steel AISI D3 is going to be carried Conclusion
out. Fc
(N)
Introduction Work Material Description
Es
Milling is a machining operation, where material Material AISI D3 Die Steel Alloy
removal from workpiece takes place utilizing a ()
Hardness 30 HRC
rotary cutter, which moves along a certain direction
(Feed). In die and mold industries the
implementation of tool path strategies has increased
Ra
to an extent that it has turned in to a common Process Parameters (μm)
practice today. The main reason for this is it not only Parameter Low (-1) Medium (0) High (+1)

improves productivity and quality but also decreases Spindle Speed

(rpm)
1800 2500 3200

the machining time. Tool path strategy influences Feed Rate 150 200 250
the output qualities of the product largely. (mm/min)
Step increment 0.4 0.7 1
Trochoidal milling involves using an end mill to (mm)
create a series of small disjoint loops over the length
of the slot. The slot width is usually higher than the
diameter of the tool, which allows it to gain an Experimental Setup
appreciable amount of radius for rotation so as to
achieve the slot of required dimensions

Objectives
The objective of this study is
BFW Gaurav BMV 35 T12 Machining of
Workpiece
Work piece after
Milling
Conclusions
• To determine the effect of Trochoidal toolpath • Cutting speed and Feed rate and step increment
strategy along with process were varied using Response Surface Method
parameters(Spindle Speed, Feedrate, Step Cutting Tool
(RSM) using Central Composite Design
increment) with respect to output quality • Mathematical models were developed by using
characteristics.(Cutting Force, Specific Cutting (RSM) while the optimization was accomplished
Energy, Surface Roughness) by adopting the desirability function which
Dynamometer Setup Roughness Test of Workpiece generates favorable machining responses such as
• To optimize the process parameters based on lower cutting force, improved surface finish and
Desirability Function. reduced specific cutting energy.
Simulation of Toolpath • ANOVA results show that the cutting conditions
Trochoidal Toolpath plays dominant role in defining the value of surface
roughness, cutting force and specific cutting
energy.
Optimized Results Using Desirability Function
Input Parameters Optimized Responses
S.no Speed Feed Step Fc Es Ra
(rpm) (mm/min) Increment (N) (J/mm^ ( μm )
3)
Trochoid is defined as a curve traced by a point at a
distance “a”, from the center of a circle of radius RSM 3200 207 1 54.48 0.5513 0.3694
“b”, as the circle is rolling on a straight line. Actual 3200 207 1 55.90 0.5434 0.3571

ACKNOWLEDGEMENT References
1. R.Suresh, S.Basavarajappa, Effect of parameters on tool wear and surface
roughness during turning of hardened steel with coated ceramic tool.
We wish to convey our deep sense of gratitude and sincere thanks to our
2. Patricia Munoz Escalona, Paul G.Maropoulos, A geometrical model for surface
guide J. Santhakumar (Sr. G) , Associate Professor and we would like to roughness prediction when face milling Al 7075-T7361 with square insert tools.
thank our Professor and Head, all technical and non-technical staffs of 3. S.H.Tomadi, J.A.Ghani, C.H.Che Haron, H.Mas Ayu, R.Daud, Effect of cutting
parameters on surface roughness in end milling of AlSi/AlN metal matrix
Department of Mechanical Engineering, SRM University, Chennai. composite.
4. Abram Pleta and Laine Mears, Cutting force investigation of trochoidal milling
in nickel based super alloy.