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ADVANCED

MACHINING
PROCESS (GROUP
PROJECT)
EN. NOOR HAKIM BIN RAFAI

GROUP MEMBERS

MUHAMMAD SYAFII BIN

RAHMAN BIN BIDIN

SALMAN BIN HABBA

CD130110

MUHAMMAD MUHAYMIN BIN HASNI

CD130161

CD130170

INTRODUCTION
HIGH SPEED MACHINING
(HSM)

The use of higher spindle speeds


and axis feed rates to achieve
high material removal rates
without a degradation of part
accuracy or quality.

ELECTRICAL DISCHARGE
MACHINING (EDM)

Using thermal energy to machine


electrically conductive parts.

No direct contact between the


electrode and the work piece.

Carried out by means of electric


sparks that jump between two
electrodes subjected to a voltage

Submerged in a dielectric fluid.

The tool electrode shape is


reproduced mirror wise into a
work material.

HIGH SPEED MACHINING


(HSM) PROCESS

ELECTRICAL DISCHARGE
MACHINING (EDM) PROCESS

DESIGN OF EXPERIMENT
(DOE)

ANALYSIS

The
main target of this project is to get a roughness between 23.

To get the roughness reading we are using roughness tester


machine Mitutoyo SJ400.

We take 3 times of reading for each machine result to get an


average of the roughness reading.

High Speed Machine (HSM)


Analysis
1)

We were given a Mitsubishi VC4MCD0200 as our tools.

2)

From the catalog we can get the information and parameters of


the tools :

3) We set three types of parameter to get the best roughness surface.

Parameter 1

Parameter 2

Parameter 3

Spindle Speed

30000

25000

10000

(RPM)
Feed Rate

4500

5000

6000

(mm/min)
Depth of cut (mm)

0.18

0.18

0.18

Diameter of feature

25

15

15

(mm)
Thickness (mm)

0.5

0.5

Machining time

1.5

1.1

(min)
Roughness ()

0.53+0.36+0.47=

1.67+1.05+1.28=

2.55+2.53+2.48=

0.45

1.33

2.52

Electrical Discharged Machine


(EDM) Analysis

1)

We use brass as our electrode (brass has a lower hardness then


mild steel).

2)

We set the roughness parameter to 1.6 to achieved surfaces


roughness between 2- 3 (the setting of the machine has an
error).

3)

The result we get is 2.11, 2.09 and 1.90 so the average is 2.03.

MACHINING TIME
HIGH SPEED MACHINING (HSM)

1)

ELECTRICAL DISCHARGE MACHINING (EDM)

Overall length covered by the

cutting tool:
L = 44mm + 31.4 mm + 18.9 mm
+ 6.3 mm = 100.8 mm
2) Formula for machining time:
Tm =
L = 100.8 mm
A = =
= 0.06 minute
Thickness
= 0.5 mm
Depth of cut = 0.18 mm
= 2.8

Tm = x 2.8 = 0.05 minute

The machining time for EDM to


complete the process is 35 minutes.

It takes much longer time to complete


the machining process compare to the
HSM.

CONCLUSION

We
complete this project successfully.

We are able to understand the different between both High Speed Machining
(HSM) and Electric Die Machine (EDM).

The most obvious different between both machining is the time taken.

Surfaces roughness for each process in the ranges of 2- 3.

The HSM took shorter time to complete the process compare to EDM.

For HSM process, we obtain tool wear of cutting tool will affect the surface
roughness.

Feed rate and spindle speed play an important role for obtain the desired
surface roughness for HSM process.

For EDM process, the tool wear will be affect for surface roughness.

Tool made from brass and the tool wear quicker and electric die machine
created for higher surface roughness for EDM process.