CE 2: Tool Wear in High Speed Milling Competency Demonstration Report

This report, a Competency Demonstration Report (CE 2), focuses on tool wear in high-speed milling, a critical aspect of production engineering. The project, conducted at International Islamic University Malaysia from 2015-2016, investigates the effects of machining parameters on tool wear, aiming to determine optimal cutting parameters for minimizing flank wear in mild steel during high-speed face milling. The report details the project background, objectives, and the author's role as a Production Engineer, including information gathering, analysis of milling techniques (peripheral and face milling), and the application of engineering knowledge. The report also identifies issues such as high tool costs and the need for efficient production, proposing solutions like adopting new technologies and hard milling techniques to enhance efficiency. It includes an overview of the project, the author's contributions, and a review of the analysis of machining parameters using Central Composite Design (CCD) and ANOVA. The project highlights the importance of understanding and optimizing tool wear to improve manufacturing processes.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 2
ZAKARIA AFRAH

CE 2.1 Project Information
Name of the project: Tool Wear in High Speed Milling
Location of the project: Malaysia
Project Duration: 2015-2016
Organization: International Islamic University Malaysia
Role and Designation during the time: Production Engineer
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
The concept related to the mining is the main idea behind the designing of the project.
The process of cutting down the edges of the surface and to provide the required surface design
is the process of milling. Peripheral milling operation is when the axis of rotating of the cutter is
parallel to the surface of work pieces. There are different kind of milling procedures including
the lab milling, slotting and the side milling. The face milling is the operation in which the axis
of rotation of the mills cutter are perpendicular the work pieces surface. Different parameters
related to the milling operation are also included in this project for the better understanding of
the project. Different methods like conventional and the nonconventional methods along with the
tools were given in details in the project with the experimental analysis.

CE 2.2.2 Objectives developed for the project
The objectives of these projects are
 To analyse the effect of different machining parameters on tool wear during high speed
milling.
 To analyse the tool wear produced under high speed milling.
 To determine the optimum cutting parameters that minimize flank wear during high speed
face milling for mild steel.
 To study the relationship between flank wear and machining time.
CE 2.2.3 My area of work
I was assigned for this project which is based on tool wear in high speed milling. I have
collected all the information related to the project from internet and different books. I have
disused the concepts and the regarding types related to the milling process. I have included
different methods and the topics related to the concept of tool wear in high speed milling. I have
stated all the classifications and the related feature of the milling technology that can be utilized
in different ways. I have also made the documentation of the whole project with respect to the
detailed specifications and plan of making the project.

CE 2.2.4 Project Group
Figure 1: The hierarchy of the project
CE 2.2.5 My responsibilities throughout the project
I have taken the responsibility of making this project based upon the concept of tool wear
in high speed milling for the completion of my degree in the Production Engineering. I have also
taken the responsibility to assure that the information which were collected for making this
project, are true and relevant to this project. I have also taken the functionality to execute this
project and to define the future applications related to the milling technique.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
In case of manufacturing industry milling is one of the most important machining
operations. The primary functionality of this machine is to produce several products having
different geometrical shapes. Face milling is one of the most popular techniques which is used
for better finishing in case of generating accurate and complex geometry. Multipoint cutting tool
is mainly used in this. In case of high speed milling the depth is smaller than that of the
conventional milling. The primary parameter related to the tool life is that the amount of the
cu9tting time. Tool life can be defined by operating the cutting tool. To minimize the cost the
tool life ought to be increased. The correlation between the number of inserts and the tool life is
about to study whether the tool life reduces or become longer as the number of inserts reduces.
Optimization is one of the most important techniques and the most important term that is related
with the customization is the material removal rate (MRR). The face milling method is used in
order t create a plane surface with smooth finish.
Figure 1: Face milling
High speed face milling is one of the modern technologies which is used due to its better
efficiency. It reduces the manufactured cost and production time. The cutting tool of the milling
machine should be coated with Al2O3, TiCN, TiN, CBN and PCBN. Hard milling is used to

achieve more accuracy and efficiency. There are several parameters related to the milling system
and those are considered as the cutting parameter. The parameters are s follows.
a) Spindle speed (rpm)
𝑛= (1000 × Vc)/πD(𝑟𝑒𝑣/𝑚𝑖𝑛)
Where, 𝑛=𝑠𝑝𝑖𝑛𝑑𝑙𝑒𝑠𝑝𝑒𝑒𝑑 (𝑟𝑒𝑣/𝑚𝑖𝑛), 𝑉𝑐=𝑐𝑢𝑡𝑡𝑖𝑛𝑔𝑠𝑝𝑒𝑒𝑑 (𝑚/𝑚𝑖𝑛) and
𝐷=𝑐𝑢𝑡𝑡𝑒𝑟𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝑚𝑚)
b) Feed rate (mm/min)
𝑉𝑓= 𝑓𝑧×𝑧×𝑛 (𝑚𝑚/𝑚𝑖𝑛)
Where, 𝑉𝑓= 𝑓𝑒𝑒𝑑𝑠𝑝𝑒𝑒𝑑 (𝑚𝑚/𝑚𝑖𝑛), 𝑓𝑧=𝑓𝑒𝑒𝑑𝑝𝑒𝑟𝑡𝑜𝑜𝑡ℎ
(𝑚𝑚/𝑡𝑜𝑜𝑡 ),ℎ 𝑧=𝑛𝑢𝑚𝑏𝑒𝑟𝑜𝑓𝑡𝑒𝑒𝑡 andℎ 𝑛=𝑠𝑝𝑖𝑛𝑑𝑙𝑒𝑠𝑝𝑒𝑒𝑑 (𝑟𝑒𝑣/𝑚𝑖𝑛)
The frank wire and the tool wear are used as the important techniques which can be
implemented for getting different types of shapes. The optimization technique is used to decrease
the cost and the production time.

Figure 2 : Classification of optimization techniques
There are several conventional and nonconventional methods which are used for the
optimization. Response Surface Design is one of the methods which can be implemented in case
of making the system more advanced in terms of making it be utilised in designing, formulating,
developing, and analyzing new scientific studying and products.
CE 2.3.2 Engineering knowledge and skills applied in the project
In this project I have applied the knowledge learnt during my bachelor degree in
Production Engineering. The basic concept related to this project is the milling technique which
is also important from the point of view of making several objects with perfect shapes. I have
applied several concepts related to the flowchart and the analysis which are used in this report
with better efficiency. The concepts related to the speed range of the spindle and the organisation
is also utilised in this project. Different concepts about the instruments and the tools have been
also utilised in this project.

CE 2.3.3 Accomplishment and task performed
I have done mainly the analysis based upon the information related to the milling
technique. I have also created a flowchart which is used here to find out several aspects of the
milling technique. I have included all the data which can be considered as the structure of the
organisation and also it can help in understanding of the work flow of the project.
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
There are different types of issues related to the milling technique. The primary issues
related to this system are given following.
 In some cases the cost is really very high for using the tools related to milling.
 The amount of the production team is also very high in case of mother.
 The efficiency sometimes is decreased for using a lot of time.
2.3.4.2 Solutions
From the project it is cleared that the organisation has several issues in case of milling.
The possible solutions found was to overcome the cost related issues the focus should be given
on new technologies which can be utilised with the faster response. Use of the hard milling and
other features has increased a lot of efficiency which can be very useful for this system.
CE 2.3.5 Plan to produce creative and innovative work
I have created the entire project based on some plan which can be utilised as the future
scope of the project. This project can be used in the understanding of new technologies and the

important parameters. This project can be utilised in several big projects in which lots of hard
ware are used.
CE 2.3.6 Collaborative work
I had a hands on experience in the field of work. It helped me to gain a lot of experience
during the working of this project. I was able to follow the project objectives and collaborate
with my team mates to produce the best quality work. I had regularly communicated with the
department head of the project who had helped me to complete the project smoothly and provide
the best quality project.
CE 2.4 Project Review
CE 2.4.1 Project Overview
This section talks about the outcome and investigation of utilizing focal composite plan
examination in advancing the machining parameters in rapid face processing. In this analysis 13
runs were performed to confirm the impact of flank wear in confront processing operation.
Additionally, the general time of embed to fall flat were evaluated. The number of runs is
dictated by Central Composite Design (CCD) and the outcome is broke down after all the
processing operations are finished by performing investigation of difference (ANOVA) in
Design-Expert programming rendition 6.0.8.
CE 2.4.2 My contribution to work
I have utilised all of my knowledge and skills in this project. I have executed the whole
project with the collection and analysis of the data. For legitimate execution of the undertaking I
have arranged all the outline with a specific end goal to influence it to first rate. I have finished

this undertaking with best of my ability by contributing in the circuit configuration, arranging
and in a few operations. I have likewise composed the circuit. I have done the capacities a few
times to assess the blunders in the framework and furthermore educated those to my colleagues
and my task manage. Subsequent to testing every one of the components and capacities I have
made the documentation of the undertaking and submitted to the college.