Simulation and experimental based fundamental investigation on the surface quality of hard alloy in the mechanical milling process.

Project Title

Simulation and experimental based fundamental investigation on the surface quality of hard alloy in the mechanical milling process.

Project Area of Specialization Mechanical EngineeringProject Summary

The titanium alloys are widely used in the biomedical, aerospace and automotive industries due to

their good mechanical and chemical properties. Good surface roughness is achievable by using

expensive cutting tools. We investigate the optimum cutting parameters that could produce

the significant good surface roughness by reducing the tool cost. The control parameters were

depth of cut, feed, width of cut and the cutting speed. In order to optimize the surface roughness

quality Response Surface Methodology is employed. The responses parameters were surface

roughness and temperature. The experiments were performed in the dry, wet and MQL machining

environments. It was observed that the wet machining environment provide good surface quality.

In the recent years manufacturing industries are implementing new techniques to improve the

manufacturing performance due to which the environmental aspects are widely becoming an

important issue worldwide. Therefore, the sincere efforts are should be made in order to reduce the

impact of the industrial load on the health and on the environment. The requirement for the

environment friendly cutting processes authorized the use of techniques like the minimum quantity

lubricant MQL. Therefore, a limited research work has been reported using the MQL technique.

The overall results showed that the MQL machining is the sustainable machining environment

because it reduces the number of tools required for machining, and the overall working condition is

environment friendly. The MQL machining environment also provides the better surface quality.

Project Objectives

The followings is the objectives for completing FYP.

1-Problem analysis

2-Literature review

3-Selection of material

4-Material procure

5-Experimentation

6-Data record

7-Graph

8-Investigate

Project Implementation Method

We have divided our project into 3 phase.

Phase 1 involve the literature review to identify research gap.

Phase 2 involve simulation of milling process, procuring material, experimentation.

Phase 3 involved response measurements, analysis of data and conclusion 

Benefits of the Project

The main benefit of project is that it will help in selection of cutting parameters in machining of aeroplane parts.

The project have also focused on the sustainability analysis of dry, wet and MQL milling. The project have proposed the sustainable method for machining of titanium.

Technical Details of Final Deliverable

The following is the details of final deliverables.

1- Simulation

2- Cutting parameters for milling of titanium 

3- Research paper publication

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther IndustriesCore Technology RoboticsOther TechnologiesSustainable Development Goals Good Health and Well-Being for People, Industry, Innovation and Infrastructure, Sustainable Cities and CommunitiesRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	47500
Ti-6Al-4V workpiece	Equipment	3	4500	13500
Tungsten carbide tool	Equipment	9	900	8100
Lubricant for wet machining	Equipment	1	5000	5000
Scanning electron microscope analsis of tool chips and workpiece	Equipment	9	1300	11700
Printing of Mid evaluation report	Miscellaneous	3	400	1200
CNC Machining rent	Miscellaneous	1	4000	4000
Thesis	Miscellaneous	4	1000	4000