EXPERIMENTAL ANALYSIS OF MACHINING PERFORMANCE BASED ON

SELECTED CUTTING PARAMETERS FOR SMART

CNC TURNING ENVIRONMENT

SHUHAIDI BIN MOHAMAD

UNIVERSITI TEKNOLOGI MALAYSIA

EXPERIMENTAL ANALYSIS OF MACHINING PERFORMANCE BASED ON

SELECTED CUTTING PARAMETERS FOR SMART CNC TURNING

ENVIRONMENT

SHUHAIDI BIN MOHAMAD

A thesis submitted in partial fulfillment of the

requirements for the award of the degree of

Master of Engineering (Mechanical-Advanced Manufacturing Technology)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

JUNE 2014

iii

To my beloved family, Father, Hj. Mohamad Bin Lebai Ibrahim, Mother, Hjh.

Kuntom Binti Abdul, Wife, Noor Shaliza Binti Zainal Abidin, my Sons and Daughter,

MuhammadAmirul Farish, Nur Aliya Nabila, MuhammadAmirul Hakimi, Brothers

and Sisters. Thank for all your support.

iv

ACKNOWLEDGEMENT

In the name of Allah, the most Gracious and most Compassionate

I would like to thank Allah Almighty for blessing and giving me strength to

accomplish this thesis. A special thanks to my supervisor, Dr. Aini Zuhra Binti

Abdul Kadir who greatly helped me in every way I need to go through this final

project.

I am also indebted to Majlis Amanah Rakyat (MARA) for funding my degree

of Master of Engineering. I would like to express my sincere appreciation to all of

my friends and colleagues in Kolej Kemahiran Tinggi Mara Balik Pulau for coloring

my daily live and helped me in one-way or another. Their views and tips are useful

indeed.

Deepest gratitude to my parents, all of my family, who give me a real love,

pray, support, and all they have for the continuous encouragement and patience

within this study period.

v

ABSTRACT

The purpose of this study is to analyze turning performance of Aluminium

Alloy 6061 based on selected cutting conditions such as cutting speed, feed rate and

depth of cut, in terms of acceptable range of surface roughness, with the integration

of STEP-NC as a data structure. STEP-NC, an acronym for Standard for the

Exchange of Product Model Data for Numerical Control is developed by the ISO

committee with the intention of replacing the outdated G-codes used for machine

execution. G-codes only contain point to point instructions directing the machine to

move and machine the parts with lack of intelligence. Important machining

parameters such as tolerance information, feature information and cutting tools

information are missing and cannot be utilized at CNC level. In addition, it

commonly embedded with specific extension of different vendors’ added code

depending on its controller making it lacks of interoperability. STEP-NC on the other

hand provides comprehensive data structure and may provide information such as

material properties, value of surface roughness, part feature and workingstep for the

process. In this study, dry cutting operations of a 100mm Aluminum Alloy 6061 bar

were turned into a 50mm length and 24mm final diameter based on the

combinations of various cutting parameters set using Design of Experiments (DOE)

method. The experimental results were statistically analyzed to study the influence of

cutting parameters on surface roughness. Based on this, to suit the smart CNC

turning environment, regression model were developed and were used in Graphic

User Interface (GUI) algorithm in STEP-NC for the surface roughness value output.

The outcome of this study shows that feed rate, cutting speed and depth of cut have

significance effects on the surface roughness and the best surface roughness

condition is achieved at a low feed rate 0.07 mm/rev, high cutting speed 280 m/min

and depth of cut 0.1 mm. The results also show that the feed rate has big effect on

surface roughness followed by cutting speed and depth of cut.

vi

ABSTRAK

Tujuan kertas penyelidikan ini adalah untuk mencari prestasi pemesinan

untuk kekasaran permukaan Aluminium Alloy 6061 berdasarkan memotong syarat

(kelajuan pemotongan, kadar suapan dan kedalaman pemotongan,) dengan integrasi

STEP-NC. STEP-NC menyediakan struktur data yang komprehensif dan berupaya

memberikan maklumat seperti sifat bahan, nilai kekasaran permukaan, ciri bahagian

dan langkahkerja untuk proses pemesinan yang dibuat. Dalam kajian ini, operasi

pemotongan kering (tanpa menggunakan cecair memotong) bar 100mm Aluminium

Alloy 6061 telah dilarik sepanjang 50mm panjang dan 24mm diameter akhir

berdasarkan kombinasi pelbagai parameter pemotongan yang telah ditetapkan

menggunakan kaedah Rekabentuk Eksperimen (DOE). Mengkaji hubungan yang

wujud di antara panjang, pada diameter tertentu, dan kekasaran permukaan stok bar

dalam operasi perubahan yang tidak disokong dalam usaha untuk mengurangkan sisa

persediaan dalam mengubah operasi. Konsep Rekabentuk Eksperimen (DOE) telah

digunakan untuk uji kaji perlu. Keputusan eksperimen telah dianalisis secara statistik

untuk mengkaji pengaruh parameter proses kepada kekasaran permukaan. Model

regresi telah dibangunkan dan digunakan di dalam algorithma Antara Muka

Pengguna Grafik (GUI) dalam STEP-NC bagi mendapatkan nilai output kekasaran

permukaan. Analisis varians mendedahkan dalam kajian ini adalah bahawa kadar

suapan, kelajuan pemotongan dan kedalaman pemotongan mempunyai kesan penting

kepada kekasaran permukaan dan keadaan kekasaran permukaan yang terbaik

dicapai pada kadar suapan yang rendah 0.07 mm / rev pemotongan tinggi kelajuan

280 m / min dan kedalaman potong 0.1 mm. Keputusan juga menunjukkan bahawa

kadar suapan mempunyai kesan yang besar kepada kekasaran permukaan diikuti

dengan kederasan pemotongan dan kedalaman pemotongan.

vii

CHAPTER TITLE PAGE

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF ABBREVIATATIONS xvi

1 INTRODUCTION 1

1.1 Background of the Study 1

1.2 Statement of the Problem 4

1.3 Research importance and impact 7

1.4 Objective of the Study 8

1.5 Scope of Study 9

TABLE OF CONTENTS

viii

2 LITERATURE REVIEW 10

2.1 Introduction 10

2.2 Single Point Machining 11

2.3 Cutting Tool Element for Turning 12

2.4 Aluminum Alloys 13

2.5 Surface Roughness 15

2.5.1 Arithmetical Mean Roughness (Ra) 17

2.6 Process Design and Improvement with 17

Design Experiments

2.6.1 Factorial Experiments 18

2.7 STEP-NC as a Medium for 20

Intelligent Machining

2.7.1 STEP-NC Data Model 23

2.8 Analysis of NC vs. STEP-NC program 24

2.8.1 Code arrangement 25

2.8.2 Character of code 26

2.8.3 Information in coding 28

ix

3 METHODOLOGY 30

3.1 Introduction 30

3.2 CNC Turning Operation 31

3.2.1 External Tool Holder - 34

PDJNL2020-43

3.2.2 Indexable Insert for Turning- 35

DNMG110404N-GU

3.2.3 Mitutoyo Surface Roughness 36

Tester SJ-400

3.3 Experimental Setup 38

3.4 STEP-NC Framework of Machining 43

Performance for Surface Roughness

3.5 STEP-NC Part 21 File 45

3.5.1 Part 21 File Header 45

3.5.2 Workpiece definition 46

3.5.3 Manufacturing Feature 47

3.5.4 Turning Operation 49

3.5.5 Turning Machine Tools 52

3.6 Graphic User Interface (GUI) 54

x

4 RESULTS AND DISCUSSION 56

4.1 Experimental Results 56

4.2 Part 21 File Program 57

4.3 Graphic User Interface (GUI) 61

4.4 Result of Machining Parameters 62

4.4.1 Feed Rate 63

4.4.2 Cutting Speed 64

4.4.3 Depth of Cut 65

4.4.4 Graphical Plot for 66

Surface Roughness

4.4.5 Regression Analysis Equation: 68

5 CONCLUSION AND RECOMMENDATION 70

5.1 Enhancements of STEP 70

5.2 Recommendations 72

REFERENCES

Appendices A-Others

73

78-92

xi

TABLE NO. TITLE PAGE

2.1 Surface Finish Tolerance in Manufacturing 16

Aluminum Alloy 6061

2.2 Character of code 27

2.3 The ability of NC and STEP-NC program 28

2.4 Information in NC and STEP-NC program 29

3.1 Test Matrix 40

3.2 The Range of Variables for the 41

Cutting Conditions

3.3 The cutting conditions and the groups 42

of experimental testing

4.1 Data for surface roughness by 57

using full factorial design

LIST OF TABLES

xii

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Fishbone diagram with factors that 3

influence on surface roughness

1.2 Typical composition of 4

Aluminum Alloy 6061

1.3 Difference between the current situation 6

and the use of the STEP-NC

2.1 The main cutting data/tool elements for 13

turning tool applications.

2.2 Mechanical Properties of 14

Aluminum Alloy 6061

2.3 Arithmetical Mean Roughness (Ra) graph 17

2.4 General model of a process 18

2.5 Design geometry of the 2 factorial design 19

2.6 Test matrix of the 2 factorial design 19

xiii

2.7 STEP-NC CAD/C APP/CAM/CNC 21

integration.

2.8 General description of the data model 24

and the data flow.

3.1 CNC Turning DMG CTX 310 Glidimiester 31

3.2 CNC Turning Operation 32

3.3 Technical Data for CNC Turning 33

DMG CTX 310 Glidimiester

3.4 Tool Holders for Negative Insert 34

3.5 Indexable Inserts for Turning 35

3.6 Device Mitutoyo SJ400 for 36

Surface Roughness

3.7 Definitions of Surface Roughness Terms 37

3.8 Surface Roughness compensation 38

3.9 Illustration of workpiece dimension 39

3.10 STEP-NC Framework of Machining 44

Performance for Surface Roughness

3.11 Entity of Header in Part 21 File 46

3.12 Entity of Workpiece in Part 21 File 47

xiv

3.13 Entity of Manufacturing Features in 49

Part 21 File

3.14 Facing radial and axial tool movement 50

3.15 Entity of Turning Operations in Part 21 File 51

3.16 Entity of Surface Roughness in Part 21 File 52

3.17 Turning Machine Tool 53

3.18 Tool Path representation 53

3.19 Turning machine strategy dialog (GUI) 54

4.1 Part 21 File 59

4.2 Part 21 File for Surface Roughness 60

4.3 Turning machine strategy dialog 61

in acceptable mode

4.4 Turning machine strategy dialog 62

in rejection mode

4.5 Main effects plot for Ra Vs Feed Rate 63

4.6 Main effects plot for Ra Vs Cutting Speed 64

4.7 Main effects plot for Ra Vs Depth of Cut 65

4.8 Normal Probability Plots of Residual 66

for Surface Roughness

xv

4.9

4.10

4.11

Residual Fitted Plots for Surface Roughness 67

STEP-NC Interface Algorithm 68

Data for surface roughness 69

xvi

LIST OF ABBREVIATATIONS

i Material Safety Data Sheet MSDS

ii Computer Numerical Control CNC

iii Revolution Per Minute RPM

iv Analysis of Variance ANOVA

v Machine Condition Monitoring MCM

vi Surface Roughness Ra

vii Standard for the Exchange of Product Model Data STEP-NC

viii International Standard Organization ISO

viiii Design of Experiment DOE

1

CHAPTER 1

INTRODUCTION

1.1 Background of the Study

Turning is a machining process in which a cutting tool, typically a non­

rotary tool bit, describes a helical toolpath by moving more or less linearly while the

workpiece rotates. The tool's axes of movement may be literally a straight line, or

they may be along some set of curves or angles, but they are essentially linear.

Turning is also one of the most important processes in manufacturing to make

various products and parts where the material removal process is made according to

the desired design and shape. It may also produce accurate and precise results

compared with other processes.

The modern technologies of turning are directed toward development of

optimization tables that list specific feed rates, spindle speeds, and depths of cut for

different materials. These tables then will be the standard used in industry as a source

2

of reference, when making various turning operations from one job to another where

the machining parameters of each may be quite different. The time, material, and

tooling costs associated with the experimental steps needed to be properly planned

according to the appropriate machining parameters to eliminate high setup costs as

well as to sustain the product quality.

In the process of machining, surface roughness (Ra) is very important

indicator to ensure good quality products. Surface roughness is a result very critical

in the sense that in some industries such as medical implant, surface roughness can

result in injury to the user if the Ra value exceeds a certain limit. To ensure that Ra is

within range, various factors need to be considered such as machining parameters,

workpiece shape and material, cutting tools properties and also cutting phenomena

such as vibrations, cutting force and chip formation. The cause and effect diagram

shown in Figure 1.1 highlights these factors that need to be considered in order for

manufacturers to maximize their production.

To suit the smart CNC turning environment, one way to mathematically

represent the relationship of the abovementioned parameters is by using Design of

Experiment (DOE) techniques. DOE is used to generate models, including regression

in order to get a model that generates an accurate prediction of surface quality which

were used in STEP-NC and gives a robust mathematical representation of the related

parameters. Such models will then leads to optimization and efficient machining

process.

3

Figure 1.1 : Fishbone diagram with factors that influence on surface roughness [1]

Aluminum Alloy 6061 is used as a main material because of its good

mechanical properties. It also exhibits good weld ability [2]. It is one of the most

common alloys of aluminum for general purpose use. Originally called "Alloy 61S,"

it was developed in 1935. This material commonly used for wide purposed such as

construction of aircraft structures, yacht construction, including small utility boats,

automotive parts such as wheel spacers and for the manufacture of aluminum cans

for the packaging of foodstuffs and beverages. It is known as a precipitation

hardening aluminum alloy, containing magnesium and silicon as its

major alloying elements as shown in Figure 1.2.

4

Component Amount (wt.%)

Aluminium Balance

Magnesium O.S- 1.2

Silicon O A o (B

Iron Max. 0.7

Copper O. 15-0.40

Zinc Max. 0.25

Titanium Max. O. 15

Manganese Max. O. IE

Chromiium 0.04-0.35

Others 0.05

Figure 1.2 : Typical composition of Aluminum Alloy 6061 [2]

1.2 Statement of the Problem

The quality of machined components is evaluated by how closely they adhere

to set product specifications of length, width, diameter, surface finish, and reflective

properties. For machining, surface roughness is harder to attain and track than

physical dimensions are, because relatively many factors affect surface roughness.

Some of these factors can be controlled and some cannot. Controllable process

parameters include feed rate, cutting speed, tool geometry, and tool setup. Other

factors, such as tool, workpiece and machine vibration, tool wear and degradation

and workpiece and tool material variability cannot be controlled as easily. There are

5

usually based on experience and trial and error to obtain suitable cutting data for

each cutting operation involved in machining a product. Therefore, such traditional

machining practices will results to high setup time with less efficiency

In traditional machining, lack of information available that can be obtained

during machining where during machining process, machine tools are executed based

on simple point to point geometry data by means of NC codes known as ISO 6983

(G-code). It contains low level information and has been used for more than 60

years. It consists of geometric coordinate information in (point to point form)

directing the machine to move and machine the parts. This code lacks of other

important machining parameters such as tolerance information, feature information

and cutting tools information. In addition, it commonly embedded with specific

extension of different- vendors added code depending on its controller. Realizing

these drawbacks, ISO committees have been working to improve this existing

standard. The outcome of this international effort leads to the development of a new

standard called Standard for the Exchange of Product Model Data for Numerical

Control (STEP-NC) or also known as ISO 14649 was published.

With the introduction of STEP-NC, high level data information such as

material properties, parts tolerances, part features and surface roughness value to be

incorporated during machine execution. STEP- NC may recognize part feature,

surface roughness, dimension of the stock part and material properties at CNC level

and therefore enables further optimization and analysis to be conducted. It enables

bi-directional data flow making it an intelligent machining platform. It may also

provide interoperability as it eliminated the vendor specific extensions. Figure 1.3

illustrates the difference between the traditional machining practice and STEP-NC

interface. This will leads to a smart CNC turning environment.

6

Current situation STEP-NC interface

ISO 6963

1

VoNQ5 G54N10 G91N15 GOC X<IO(] Z20dN20 3120D F20DT2 M65N25 GDI Z10D M3N30 G01 Z20DN35 GOO X400 ZAWN40 U3D

"~| Post Prozessor|

Ivender specific

format

INC controller

-low level information- simple movement- simple switching- no high level curve

format- no geometry item

information- vendor specific

extensions- for one machine too I and

one machine setup only

C4DCAM

s t e p ^

#1 =WDrkp ecei’demo1,.. #3,.): #2=aiis2pl3cefir enl3d{....); #3=Hock(_.>;

4 = w d r k p la r i{ . . . { £ 5 ,# S ))

#5=i«cifcin(pfepip[f\. #7 ,=a.) #A=lo3c _toDl{ld' .# 1DQ); # 7 = n o u " d _ h a lE i , d ', . . . } ;

ng{._);

ncNC planning and design

shop floor

NC controller

+ high level information + object oriented description + use of STEP geometries + vendor neutral + processable on different

mac hi nes + enables bidirectional data

flow

Figure 1.3: Difference between the current machining situation and the use of the

STEP-NC [4]

Since then, a lot of effort and studies has been performed to enhance the

capability of this new standard. For example, an enabled machine condition

monitoring system for adaptive execution of a STEP-NC based optimization

controller has been realized and developed for feed-rate optimization [3]. Therefore,

in supporting such effort, this study intends to portray how the comprehensive data

provided by STEP-NC can be utilized at CNC level. For example, in traditional

machining, in monitoring the machining parameters with respect to the desired

surface roughness values, machined parts were first measured to obtain the Ra values

using a surface roughness instrument. Following that, a series of analysis should be

performed in order to obtain the right parameters for the right surface roughness.

These procedures are very time consuming, reduce the machining efficiency and

high in cost. With the use of STEP-NC, the values of Ra after machining can be

monitored and embedded with a developed algorithm.

7

1.3 Research importance and impact

The importance of this research is to bring awareness of an advanced

machining environment especially towards local manufacturing industry in Malaysia.

STEP-NC is the first NC program that contains details about the steps to complete

machining and easily understood by the user. It contains a description of tools,

machining strategy and machining processes that are not available in ISO 6983

before. So, any loss of information to abstract movements and switching information,

as in the case of conventional programming interfaces, is avoided [4]. As STEP-NC

can bring ease and agile data transfer, it is an opportunity to develop a system that

may replace the old system thus it makes variety in manufacturing industry.

Other significant impact of this research is to promote the advantages of

STEP-NC. This will open an opportunity to hold cooperation between researcher in

universities, manufacturing industries, users, software developers and CNC vendors.

Consequently, this research brings understanding to ISO 14649 fundamental and

concept behind it, as the standard is the brain to the key in developing software to

generate STEP-NC code. ISO 14649 part program is generated by clicking the

generate code button. The program is based on workpiece and machining working

steps in a physical file text. This file text can be saved to a selected directory folder

and can be edited by the user based on manufacturing features, strategies and tools.

When the user has finalized the part program, it can be sent to the machine controller

that tallows bidirectional data flow. Apart from that, the study aims to promote the

understanding of ISO 14649 fundamentals and concepts, as the standard that can

store various machining data in executing CNC machines via STEP-NC codes and

instructions.

In the future, STEP-NC promise great profits to current manufacturing

environment where it does not have to depend on CNC machine functions that need

post-processors. The vision is to have a STEP-NC Controller that is open, intelligent

and interoperable (Xu et al., 2006). In this way, G & M code is not necessarily

needed to be generated continuously to suit various kind of CNC controller

functions. Data transfer can also be done at anytime and anywhere. With STEP-NC,

8

the process cycle of machining operation can be reduced. Correction of machining

data can be done directly at shop floor stage where the STEP-NC controller is

success to develop. Hereafter, data can be shared all over the world in a more

effective way. STEP-NC controller not only can machine part due to the machine

movement but it will provide comprehensive information for better understanding of

understand of the overall machining process which includes the feature information,

its geometry, tolerances, cutting tools data as well as its machine technology.

Since STEP-NC potentials have attracted a lot of research interests in the

recent years, it could may become reality and give a lot of benefits such as ease of

use in terms of programming data which will be used on different types of CNC

machines or vendors, and it also would save consumers or manufacturing industry in

terms of cost, manufacturing time and delivery and also will enhanced profit for the

manufacturing industry.

1.4 Objectives of the Study

While there are many machining optimization parameters that have been

developed and tabulated, an area that has been overlooked is to find the best or

suitable parameters of speed rate and cutting speed for machining Aluminum Alloy

6061. Thus, the choice of optimized cutting parameters becomes very important to

control the required surface quality.

At the same time, the emergence of STEP-NC found to be a right solution

towards optimization and knowledge utilization during machining. Therefore, the

objective of the study is:

i. To determine optimum cutting parameters for better machining performance

utilizing high-level data (STEP-NC).

9

1.5 Scope of Study

In the course of this study, some scope has been identified to achieve the

research objectives and as a passing reference in this study. With the research

specialization, this study can be done better and more organized. Among the scope of

this study are:

i. Utilize high-level data (STEP-NC) for development of smart CNC turning

environment

ii. Analyze machining performance of an Aluminum Alloy 6061 workpiece

material for better surface quality such as surface roughness

iii. Identify suitable cutting parameters such as cutting speed, feed rate, depth of

cut and workpiece dimension

iv. Conduct experimental analysis based on design of experiments (MINITAB)

to suit smart turning environment.

73

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76

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