This study investigates end-milled surfaces of HDPE-MWCNT polymer nanocomposite. The feed rate and the cutting speed are varied and their effects on the surface roughness are investigated in detail. The relationship between the surface roughness and the processing parameters are investigated by using a response table and a response function. In addition, the relationship is also discussed in terms of the Deborah number which characterizes viscoelastic behavior of polymeric materials.
Conventionally, tool wear is very high or fracture when processing high hardness steel by milling method. So, we attempted to design a fixture apparatus for hybrid machining process (HMP) by ultrasonic vibration using finite element method. Now this fixture apparatus has been manufactured. We can do many types of hybrid machining experiments using this fixture. And then the milling machining was conducted to compare the effects of the ultrasonic vibration. The results showed that the tool wear and surface roughness with ultrasonic vibration was smoother than without the fixture vibration. This result could be explained as accelerating the heat transfer by ultrasonic vibration.
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