Parameter optimization on rubberized fly ash geopolymer in milling process in minimizing tool wear

Abstract

Geopolymer is a new type of sustainable material which is produced by using industrial by-product. Recent articles showed that geopolymer materials have good machining property. However, the rubberised fly ash geopolymer (RFAG) has not been well investigated. Besides, the machining optimization also covered on natural fly ash geopolymer. So, this research was carried out to investigate the best parameter settings of machining RFAG material with respect to tool wear and the most significant parameters with respond to tool wear. The RFAG samples were machined by CNC milling machine. The cutting speed, feed rate and depth of cut were selected as the cutting parameters. Orthogonal arrays by using L9 of Taguchi method, analysis of variance (ANOVA) and the signal-to-noise ratio are employed to find the optimal levels of the significant factor affecting and to analyse the cutting parameters on tool wear. The results showed that cutting speed was the significance factor affecting tool wear. The validation test was carried out and the minimum flank wear value (0.0745 mm) was obtained. This research proves that rubberised fly ash geopolymer (RFAG) is machinable and the result collected will be expanded the application of rubberised geopolymer in the industrial sectors. The mass production of RFAG will help to reduce the waste product (fly ash and rubber waste) in order to save the environment. The success of this result is significant so that RFAG can replace current material used in common machining activities.Geopolymer is a new type of sustainable material which is produced by using industrial by-product. Recent articles showed that geopolymer materials have good machining property. However, the rubberised fly ash geopolymer (RFAG) has not been well investigated. Besides, the machining optimization also covered on natural fly ash geopolymer. So, this research was carried out to investigate the best parameter settings of machining RFAG material with respect to tool wear and the most significant parameters with respond to tool wear. The RFAG samples were machined by CNC milling machine. The cutting speed, feed rate and depth of cut were selected as the cutting parameters. Orthogonal arrays by using L9 of Taguchi method, analysis of variance (ANOVA) and the signal-to-noise ratio are employed to find the optimal levels of the significant factor affecting and to analyse the cutting parameters on tool wear. The results showed that cutting speed was the significance factor affecting tool wear. The validation test wa...