MATERIAL REMOVAL MECHANISM AND SURFACE QUALITY IN MILLING OF SINTERED SOFT MAGNETIC COMPOSITES
DOI:
https://doi.org/10.11113/jurnalteknologi.v88.25338Keywords:
Machining parameters, material removal mechanism, milling process, soft magnetic composite, surface qualityAbstract
Sintered Soft Magnetic Composites (SMCs) are widely used in electromechanical industries due to their favorable magnetic properties, such as high permeability and low hysteresis loss. However, their inherently brittle mechanical characteristics pose significant challenges during machining processes, particularly milling. This study aims to investigate the fundamental mechanisms of material removal during the milling process and to optimize machining parameters in enhancing surface quality under controlled and specified machining conditions. Milling experiments were conducted by cutting groove profiles in the workpiece for every set of varying parameters, which consisted of spindle speed, axial depth of cut, feed rate, and coolant usage as varying parameters, while radial depth of cut and tool path remained fixed. Surface roughness was analyzed using Response Surface Methodology (RSM) and Analysis of Variance (ANOVA). The surface morphology of machined surface is observed by using optical microscope. The results indicate that cooling conditions, spindle speed, and axial depth of cut affects significantly the machined surface quality, where the combination of spindle speed and axial depth of cut has a more significant effect than when considered individually. The smoothest surface roughness obtained from the experiment has surface roughness with Ra value of 1.42 µm. The surface morphology of the machined surface indicates that during milling, the surface material grains are deformed, leading to deformation-induced phase transformation, and it founds out that deeper axial depth of cut could result to smoother surface finish and coolant usage not always give smoother surface.
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