PROBLEM FORMULATION

Milling parameters: cutting speed, feed per insert and depth of cut tremendously affect the operations productivity and cost because they dictate metal removal rate. As this rate increases, machining time per piece are proportionately reduces. Therefore the labor, machine and overhead cost are absorbed by each piece. Now a day, the market is so competitive and the prices are so tight that it becomes very important to find the most economical ways of machining i.e. to reduce the consumption of tools as well as to reduce the machining time. M/s Bubber Industries is manufacturing small components like Chuck Nuts, Spacers, Plugs, Dome Nuts, Castle Nuts, Nut Steering Knuckles, and Nut Lock Bearing etc. Different operations are performed on these components on various machines. Table 3.1 list the different types of milling cutters used on milling machines. Table 3.1: LIST OF MILLING CUTTERS

SR. NO. 1 2 3 4

DESCRIPTIO N Slot Cutter Side and Face Radius Form Face Milling

DIAMETER 150mm 125mm 31mm,37m m 80mm

THICKNESS 2mm,4mm 8,10,12,14mm As per requirement As per requirement

MATERIAL HSS HSS HSS HSS

The company is spending about Rs 30,000/- per month on cutting tools and the cost of milling cutters varies from 11% to 17% of the total cost of cutting tools. The month wise expenditure of cutting tools of the company is depicted in Table 3.2. The expenditure on milling cutters is quite

significant and the management of the company is interested in analyzing the said expenditure and reducing it further. Table 3.2: EXPENDITURE ON CUTTING TOOLS
EXPENDITURE ON MILLING CUTTERS(Rs) TOTAL EXPENDITURE ON CUTTING TOOLS(Rs) % OF TOTAL EXPENDITURE (MILLING CUTTER)

MONTH

MARCH-2009 APRIL-2009 MAY-2009 JUNE-2009 JULY-2009

5500 5000 4000 4600 3500

35000 30000 38000 28000 22000

15.71 16.66 10.52 16.42 15.90

Moreover, Table 3.3 depicts the product cost of major components which involve milling operations. These components are supplied to customers based at different locations and the customers have reduced the individual cost of these products as compared to the cost of last year. So, in order to reduce the loss occurring because of such price reduction, the management of the company wants to bring down the machining cost of these products on milling machines.

Table 3.3: PRODUCT COST COST PER PIECE IN THE YEAR 2008 37.90 COST PER PIECE IN THE YEAR 2009 37.56

PRODUCT Nut Steer

Plug Adjustable Screw

15.62 45.85

15.49 45.52

The companys requirement is to increase the tool life and to reduce the machining time especially in the milling operations which are performed on the conventional milling machines. It is observed that if proper milling parameters are used during operation, there is a scope of improvement in the process performance. In order to solve the above problem, it is proposed to carry out a detailed experimental analysis of the process and to modify the parameters for improved performance by using HSS milling cutters.

---------X---------

CHAPTER 4

METHODOLOGY
Optimizing of cutting parameters is valuable in terms of providing high precision and efficient machining. The main parameters in machining affecting tool wear and surface finish are axial depth of cut, radial depth of cut, feed rate and cutting speed. The user of the machine tools must

know how to choose cutting parameters in order to minimize tool wear, cutting time, cutting force and produce better surface finish under stable conditions. In solving the problem identified at M/s. Bubber industries, with the help of Taguchi Method, following methodology is proposed to be adopted:(a) The present conditions of the milling machine, available speed and feed parameters, skill of operators, material of the component to be machined and rejection rate will be studied. (b) By using high speed steel milling cutters and adopting different sets of milling parameters, the various outputs of the process will be observed with the Trial and Error approach of Taguchi Method. (c) Experiments will be designed and conducted in which all the parameters of interest varied over a specified range and results will be observed. (d) Identification of the most influencing parameters among the axial depth of cut, radial depth of cut, feed rate and cutting speed. (e) (f) (g) (h) Identification of the control factors and their levels. Experiments will be conducted again Data will be analyzed and it will be try to achieve optimum level. Verification of the experiment and future action plan.

CHAPTER -5

EXPECTED OUTCOMES
Manufacturers are always looking for ways to improve productivity without compromising on quality of manufacturing process. To this end, much attention has been directed towards optimizing the various cutting parameter of a manufacturing process for this an analysis of the different

parameter and their influence on the performance of the cutting process, is to be made with the help of different observations. By adopting the methodology as discussed earlier, the following positive outcomes are expected from the proposed work. Reduction in rejection rate of the machining components. Longer life of high speed milling cutter. Better surface finish of the machine components. Reduction in the tool costs (Specially milling cutter) of the industry. Compatibility of the HSS milling cutter to the material of the component to be machined can be predicted. The operating parameters of the manufacturing process will be found out to machine the desired components. After obtaining these positive outcomes it is expected to increase the milling cutter life and the chances of breaking/failure during milling will be avoided or minimized. It enhances the customers satisfaction and reputation of the company.