A Study of Slot Milling Factors Affecting the Machined Surface Quality of Wood - Plastic Composites
Keywords:
slot milling, wood-plastic composite, experimental design, surface roughness, burr formationAbstract
Wood-plastic composites require a molding process to fabricate composite wood products which limits the ability to create basic forms. To develop complex items, manufacturers must use a milling process, which can create for several patterns. Therefore, this research aims to investigate the milling parameters that influence the machined surface quality of composite made from rubber wood powder and recycled polypropylene. This material has advantages in high strength and moisture resistance. The milling parameters considered were spindle speeds of 330, 610, and 850 revolutions per minute, feed rates of 43, 120, and 200 mm/min, and cutting depths of 1, 3, and 5 mm. The impact of milling parameters on surface roughness and burr formation was investigated. The results revealed that surface irregularity decreased with an increase in spindle speed, but decreased with a reduction in feed rate and cutting depth. By increasing the feed rate and spindle speed while decreasing the cutting depth, burr formation was reduced. Burr formation was greater in up milling compared to down milling due to the direction of the cutting edge's rotation direction being opposite to the feed direction of the workpiece. The recommended milling parameters were as follows: a spindle speed of 850 RPM, a feed rate of 43 mm/min, and a cutting depth of 1 mm, resulting in a surface roughness of about 6.575 µm. The minimum burr formation was approximately 0.770 mm in up milling and 0.256 mm in down milling, under the conditions of a 850 RPM spindle speed, 120 mm/min feed rate and 1 mm cutting depth. The average differences between the predicted and actual milling results were 2.136% for surface roughness, 1.639% for burr formation in up milling, and 1.87% in down milling. These results can applied to improve the milling wood and plastic composites and forecast the quality of the milled surface.
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