CHAPTER ONEINTRODUCTION

1.1 BACKGROUND OF STUDYThe machining industries is faced with great challenge achieving high quality, good surface and high material removal rate with view in economizing during machining. Nowadays, lots of machines have been produced to be used for making parts such as in automotive industries, plastic industries, etc. Behind these industries, all machines have been produced by using turning and milling machine. These two machines are basic machines that are used in all machining processes to produce part machines and make the engineering process easier and efficient.CNC milling, or computer numerical control milling, is a machining process which employs computerized controls and rotating multi-point cutting tools to progressively remove material from the workpiece and produce a custom-designed part or product. This process is suitable for machining a wide range of materials, such as metal, plastic, glass, and wood, and producing a variety of custom-designed parts and products. Several capabilities are offered under the umbrella of precision CNC machining services, including mechanical, chemical, electrical, and thermal processes. CNC milling is a mechanical machining process along with drilling, turning, and a variety of other machining processes, meaning that material is removed from the workpiece via mechanical means, such as the actions of the milling machine’s cutting tools.According to (Kharade et al., 2018), the machining parameters in milling operation comprises of cutting speed, depth of cut, feed rate and number of passes. These machining parameters essentially affects the cost, productivity and quality of machining parts. The viable improvements of these parameters influence significantly the cost and production time of machined parts and additionally the quality of final items. The turning and milling operation of an essential metal machining operation that is utilized generally in ventures managing metal cutting. The choice of machining parameters for a turning and milling operation is an important task with a specific end goal to achieve. By high performance, we mean great machinability, better surface finish, lesser rate of tool wear, higher material evacuation rate, speed- rate of production and so on.

Material removing process can be mainly divided into two groups which are conventional and non-conventional machines. Conventional machining processes mostly remove materials in the form of chips by applying forces on the work material using a wedge-shaped cutting tool that harder than the material under machining condition. Example: milling, turning, grinding, etc. Non-conventional machining, usually known as advanced machining is a type of machining process where the tools are not harder than the work piece materials. For example, in EDM, copper is used as the tool material. The conventional machines are mostly integrated with computer numerical control (CNC). When it comes to machining operations, the milling system is one of the most critical and vital operations that must be considered.Furthermore, the machining quality of this type of machines are dependent on the dynamic behaviours of it throughout operation. (Ahmad A.D et al, 2015). This in turn brings to our understanding the need to research, design, analyze each part and carefully note the material properties.

1.2 AIM & OBJECTIVES OF THE STUDY

This work is aimed at the design and implementation of a mini three axis milling machine using acrylic plastics, aluminum and mild steel as parts. Also, Conducting Finite Element Analysis on the structural strength, Frictional, Torsional, Vibrational and Trajectory Analysis to obtain high-performance in the operation of the system when subjected to loads or vibration.The objectives of this study are as follows:➢ To carry out research and a design that will culminate in the successful development of mini three axis CNC milling machine.➢ To utilize readily available locally sourced materials for the fabrication to achieve cost reduction.➢ To Draft the design of CNC milling machine.➢ To perform structural, frictional, torsional, vibration and trajectory analysis on the model➢ To be able to machine parts easily with high precision and accuracy.➢ To ensure the machine is portable and reliable.➢ To provide aesthetics while maintaining the performance characteristics of the system.➢ Test and analysis the result.

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