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    UNIVERSITI TE

    I 1

    KNIKAL MALAYSIA MELAKA

    Tool Wear Characterization of Carbide Cutting

    Tool Inserts coated with Titanium Nitride TiN)

    in a Single Point Turning Operation of AISI

    D

    Steel

    Report subm itted in accordance with the partial requirements of the

    Universiti Teknikal Malaysia Melaka for the

    Bachelor of Manufacturing Engineering Manufacturing Process)

    Muham mad Farouq Bin Muham mad Faisal

    Faculty of M anufacturing Engineering

    March 2008

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     BSTR CT

    This study presents tool wear characterization of carbide cutting tool inserts coated

    with titanium nitride TiN) in a single point turning opera tion of AISI D2 steel. A set

    of experiments of 20 settings of cutting speed, depth of cut and feed rate were

    performed on a CNC lathe without coolant. Surface roughness was measured by

    Mitutoyo profilometer SJ-301) and flank wear was measured by Axioskop 40 and

    the data was compiled into Design Expert software for analysis. From the result,

    cutting speed was found to be the main factor to have significant effect on surface

    roughness as well as flank wear. Depth of cut was also found to have interaction with

    cutting speed to produce significant effect to surface roughness. No interaction

    between the factors was found to give significant effect to flank wear. At the end of

    this study, optimization was m ade by suggesting the most suitable sets of parameter

    settings to produce minimum surface roughness and to produce minimum flank wear.

    Suggestion on parameter settings to obtain both minimum surface roughness and

    flank wear was also made.

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      BSTR K

    Kajian ini mendedahkan tentang sifat-sifat perkakas pemotongan sisipan karbaid

    besalu t titanium nitraid TiN) melalui proses pem otongan satu titik putaran ke atas

    keluli AIS I D2. Satu set eksperimen dengan 2 0 tetapan laju pemotongan, kedalaman

    potongan dan kadar potongan dijalankan menggunakan mesin larik CNC tanpa

    penggunaan cecair pelincir. Kekasaran permukaan diukur menggunakan Mitutoyo

    profilometer SJ-301) dan hausan rusuk diukur menggunakan Axioskop 40 dan

    maklumat-maklumat ini kemudian diisi ke dalam perisian Design Expert untuk

    dianalisa. Daripada keputusan yang diperolehi, laju pemotongan didapati menjadi

    faktor penting kepada penghasilan kekasaran permukaan dan juga hausan rusuk.

    Kedalaman potongan pula didapati memberi pengaruh kepada laju pemotongan

    terhadap penghasilan kekasaran permukaan. Tiada interaksi atau saling berpengaruh

    anatara factor didapati memberi kesan kepada hausan rusuk. Di akhir kajian,

    cadangan untuk setting parameter yang terbaik diberi bagi meminimumkan

    kekasaran permukaan dan juga meminimum kan hausan rusuk. Cadangan bagi setting

    parameter terbaik untuk mendapatkan gabungan peminimum an kekasaran permukaan

    dan hausan rusuk juga dibuat.

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    CH PTER

    1

    INTRODUCTION

    1 ackground

    Cutting tool is a very important field in the manufacturing industry.

    A

    lot of

    discussions and studies have been made to improve the quality and usage of a cutting

    tool. Cutting tools come in various types and shapes and various materials as well as

    various coating materials. These different characteristics of the cutting tool serve

    different types of applications. Cutting tool has to have certain aspect or criteria such

    as hardness toughness and wear resistance. One of the most common cutting tool

    materials is carbide.

    When speaking of cutting tool we cannot avoid the word tool wear. Tool wear is an

    area that researchers always wanted to eliminate or minimize. R educ tion of tool wear

    will result in many beneficial outcomes like cost reduction and improvement in

    machining quality. In order to improve the tool life study on the tool wear

    charac teristics is needed so that ideas of wear preven tions can be found.

    Lubrication is normally used in machining to prevent cutting at excessive high

    temperature. Basically lower cutting temperature results in longer tool life of the

    cutting tool. But in the case of cutting tool inserts with TiN coating the cutting tool

    insert will work better at high temperature.

    A

    study on wear mechanisms and

    performance done by Khrais and Lin

    2007)

    pointed out that dry cutting is better than

    wet cutting for TiN coating inserts under high speed cutting.

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    There are other various reasons to eliminate the usage of coolan t. Lubrication in the

    machine shops contribu tes about 15 percent of the production cost Schneider 2001).

    In o ther words, if use of lubrication is elim inated, the production cost can be reduced

    up to 15 percent. Lubrication also contribu tes to pollution. The waste cu tting fluid

    cannot be disposed off without treatment. This will even increase the cost of

    production. Other than water pollution, a ir pollution also takes place when coolant is

    used. During machining, air-borne mist is produced. There is a ce rtain limit fixed by

    Occupational Safety and Health Administration OSH A) to the mist produced by the

    coolant into the air. In conclusion, eliminating coolant by implementing dry cutting

    brings many benefits to the industry.

    1 2 roblem Statement

    Tool wear is inherent in machining. There are many steps and measures taken to

    reduce the effect of tool wear on cutting tools. One of the steps is applying surface

    treatment on the base cutting tool material. A popular method is applying coating

    onto the base cutting tool material by the use of physical vapor deposition PVD)

    method. By studying the behaviour of the tool wear with respect to machining

    parameters, tool life can be optimized by choosing the right machining parameters.

    The optimum tool is not necessarily the least expensive or the most expensive, and it

    is not always the same tool that was used for the job last time. The best tool is the

    one that has been carefully chosen to get the job done quickly, efficiently and

    economically Schneider 2001). Because of this, it is necessary to characterize

    specific cutting tool, coating material and w ork piece combination to understand the

    interaction between machining parameters and tool wear performance. In this study

    the combination of TiN coated carbide tool and D2 work piece was evaluated using

    single point turning under dry mach ining condition .

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    1 3

    bjective

    The objectives of this study are:

    a) To study the influence of machining param eters to the surface roughness of

    AISI

    D2

    steel.

    b) To study the influence of machin ing param eters to the tool wear of carbide

    cutting tool inserts coated with titanium nitride TiN).

    c) To define optimum process parameter settings to minimize tool wear and

    surface roughness using response surface methodology @SM) for single

    point turning of carbide cutting tool inserts coated with titanium nitride TiN )

    on AISI D 2 steel work m aterial.

    1 4

    Scope

    This study focuses on tool wear characterization of carbide cutting tool inserts coated

    with TiN. The types of tool wear to be analyzed are crater wear and

    fl nk

    wear. The

    machining process done is a single point turning operation with no coolant involved

    dry cutting). The machining parameters evaluated are cutting speed, feed rate and

    depth of cut. The w ork specim en or material machined is AISI D 2 steel. The surface

    finish of the machined work is also being taken into account. All of the

    experimentation will be done using design of experiment DOE) approach.

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    CH PTER 2

    LITERATURE

    REVIEW

    2 1 verview

    In this chapter, related published works by other researchers like journals are

    reviewed. These works or studies are the ones involving machining and cutting tools.

    Other related information mainly obtained from books and articles are also included.

    This review covers turning operation, machining parameters and cutting conditions,

    cutting tool insert carbide coated with titanium nitride), tool wear in the turning

    operation, work piece material AISI

    D 2

    steel) and the selected design of experiment

    method.

    2 2 Turning peration

    Turning operation means that when the machining process is running, the work

    material moves in a rotational direction. The machine tool used for this operation is

    the lathe machine. This is shown in Figure 2 1 The cutting tool is the section that

    will be moving. In other words, the cutting tool will feed onto the rotating work

    material. The material removal process is shown in Figure 2 2 The material is

    removed layer by layer depends on the depth of cut until the desired dimension is

    reached.

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      igure2 1: Lathe turning

    igure

    2 2:

    Turning operation

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    2 2 1 achining Parameters

    In any

    m chining

    operation , the param eters involved needs to be determined prior to

    the operation. In turning operation, the three most comm on machining parameters are

    cutting speed, feed rate, and depth of cut. These cutting parameters differ depending

    on the cutting tool and work material used and the type of operation to be done

    Schneider 2001). For example, work material with high hardness should not have

    high depth of cut that will result in shorter tool life. According to I S 0 3 6 8 5 :1 9 9 3 0 ,

    for cutting speed, the setting is determined from the surface to be machined and not

    on the diameter. Coated cutting to01 like TiN coating should not be cut at slow speed

    or the tool will not perform well and the tool life will a lso be shorter. The cutting tool

    insert and its coating will be explained in the next chapter.

    Cutting forces greatly influence the outcom e of the process where the cutting forces

    generally influenced by variation of the machining parameters. All cutting forces

    increase with the increase of the flank wear surface area. Increasing flank wear area

    results in an increasing area of contact between the tool tip and the work piece.

    A

    previous study indicated that the greater the value of the flank wear area, the higher

    the friction of the tool on the work piece and the higher heat generation occured, this

    ultimately caused higher value of cutting force Sikdar Chen 2002).

    2 3 Cutting Tool

    From metalworking point of view, a cutting tool can generally be stated as a tool

    used to remove material from a work piece work material) usually by the use of

    abrasive cutting and shear deformation . Schneider 2001) stated that for a cutting tool

    to be able to do its job efficiently, the cutting tool needs to have certain

    characteristics of which three of them are listed below.

    a)

    ardness Hardness and strength of the cutting tool must be maintained

    at elevate temperatures also called hot hardness.

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    b

    Toughness Toughness of cutting tool is needed so that tools do not chip

    or fracture, especially during interrupted cutting operations.

    Wear esistance

    Wear resistance means the attainment of acceptable

    tool life before tools need to be replaced.

    2 3 1 uttingTool nsert

    The term insert is applied when a cutting tool is screwed or clamped onto a tool

    holder to be fixed on a machine tool; where in this particular study, the machine tool

    would be a

    N

    lathe machine. Most of high-performance cutting tools use the

    insert method. Inserts are normally m ade sym metrically so that when the first cutting

    edge is dull they can be rotated , presenting a fresh cutting edge. This will effective ly

    increase the life of the tool insert. Figure 2.3 shows some different shapes of cutting

    tool insert.

    Figure 2.3: Insert shapes

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    2 3 2

    utting Tool Insert Material

    Carbide tools are one of the most com mon cutting tool material used in the industry.

    ~f

    to carbon steels and high speed steels carbide tools can machine much

    faster at higher speed. Carbide tools can also work at higher working temperature.

    Figure 2 4 show s a set of T iN-coated carbide cutting tool inserts and Figure 2 5 show

    a cutting too1 insert fixed to a holder and lathe machine.

    Figure 2 4: TiN-coated carbide cutting tool inserts

    Figure 2 5: Cutting tool insert fixed to a holder and lathe machine

    8

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    2 3 3 utting Tool oating Material

    Coating of a cutting tool is done to achieve some improving factors on the cutting

    tool insert Kalpakjian Schrnid 2001). There are many type of coating material

    used for specific applications. One of the methods to coat a cu tting tool is using the

    physical vapor deposition PVD ) method. Another technique is chemical vapor

    disposition CVD). CVD coa ting requires higher temperature that makes it unsu itable

    for coating tool steels. PVD technique to applying titanium nitride (TIN) can be done

    at a much lower temperature at 400°C Ostwald Munoz 1997). PVD also allows

    sharper corners and low er coefficient of friction.

    Titanium nitride TiN) coating is one of the many coatings applied using the PVD

    method. TiN has been one of the most extensively investigated hard coatings in

    laboratory as well as in real life applications Mo et al. 2007). study by Park and

    Baik 2007) also pointed out that TiN coating has been extensively used for surface

    coating because of its superior wear and oxidation resistance as compared to binary

    metal nitride coatings TiN coating have been found effective in cutting stainless

    steel.

    TiN coatings are known to be high in oxidation resistance which makes them

    favorable in dry cutting cond itions Smith et al. 1996). On the aspect of tool wear,

    TiN coatings can have common wear behaviour. study on wear mechanisms and

    tool performance of TiN coated inserts during machining done by Khrais and Lin

    2007) showed that TiN coated inserts have three wear stages, namely, running into

    wear, semi-steady state or gradual wear, and catastroph ic wear. This behaviour is

    also pointed out by Fang 1994) and Chubb and Billingham 1980)

    in

    their research

    papers.

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    Coating of cutting tool has to have some characteristics of which some are shown

    below.

    ardness

    high surface hardness from your coating is one of the best

    ways to increase tool life. Generally speaking, the harder the material or

    surface, the longer the tool will last.

    b)

    Wear R esistance This is the ability of the coating to protect against

    abrasion. Although a material may not be hard, elements and processes

    added during production may aid in the breakdown of cutting edges.

    c)

    Surface Lubricity high coefficient of friction causes increased heat,

    leading to a shorter coating life or coating failure. However, a lower

    coefficient of friction can greatly increase tool life.

    d)

    Oxidation Temperature

    This is the point at which the treatment starts to

    break down. A higher oxidation temperature rating improves success in

    high heat applications. Although the titanium nitride TiN) coatings may

    not be as hard as titanium carbonitride TiCN) at room temperature, it

    proves to be much more effective in applications where heat is generated.

    In general, the performance of TiN coatings is superior than others in their class and

    the current state of the art of TiN may be further enhanced in the future Smith et al.

    1996).

    2 4 oolWear

    Tool wear can generally be described as the gradual failure of cutting tools due to

    regular operation. There are many type of tool wear that includes edge wear, nose

    wear plastic deformation, mechanical breakage, crater wear and flank wear. There

    are many reasons to how these wear happen. For instance, mechanical breakage can

    be caused by excessive force that causes immediate failure or thermal forces that

    could also cause the wear. The machining parameter settings of the operation are

    known to be one of the most common factors that cause tool wear. From a study on

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    rnrface finish and flank wear using multiple regression models and neural network

    models done using turning as the machining operation, it is suggested that the best

    tool life was obtained in lowest feed rate and lowest cutting speed combination Ozel

    et al. 2007).

    2 4 1 Crater Wear

    The m ost comm on tool wear in machining operation is crater wear and flank wear.

    These two types of wear are the ones to be studied in this study. According to

    Boothroyd and Knight 2006), under very high speed cutting cond itions, crater wear

    is often the factor that determines the life of the cutting tool; crater wear becomes so

    severe that the tool edge is weakened and eventually fractures but when tools are

    used under economical conditions, the wear of the tool on its flank, which is the

    flank wear, is usually the con trolling factor.

    Crater wear occurs on the rake face of the tool Figure 2.6). It is a crater-like wear

    occurred on the surface parallel to the cutting edge. Kalpakjian and Schrnid 2001)

    suggested that the most significant factors that influence crater wear are tem perature

    at the tool-chip interface and the chemical affinity between the tool and work piece

    materials. Additionally, the factors influencing flank wear see next sub-topic) also

    influence c rater wear.

    crater \\ ear

    Figure 2.6: Crater wear

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      study by M anoj Kurnar et al. 2006) on crater wear mechanisms of TiCN-Ni-wc

    cermets during dry machining said that with the increase in speed and feed rate,

    cutting becomes steady with a consequ ent reduction in the cutting force.

    2 4 2 lank Wear

    Flank wear occurs on the relief face of the tool and is generally caused by the

    rubbing of the tool along the machined surface Figure 2.7) that causes adhesive

    and/or abrasive wear or from very high temperature machining that affects the tool

    material properties as well the work piece surface Kalpakjian Schrnid 2001).

    Figure 2.7: Flank wear

    From a study on tool wear prediction in turning by C houdhury and Srinivas 2004), it

    is suggested that the cutting velocity and the index of diffusion coefficient have the

    most significant effect, followed by the feed rate and the depth of cut.

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    2 4 3 Tool Wear Measurement

    When measuring tool wear, there are certain criteria that need to be considered.

    There are different types of i~ st ru m en ts an be used to measure tool wear. No matter

    what instruments used for measuring, the most important thing in tool wear

    measuring is the geom etry of the tool wear it self. Figure 2.8 below describes these

    geometries.

    flank wear

    t nd

    K crater width

    KH rater centre distance

    T

    cr ter

    depth

    Figure 2.8: Tool wear on turning tools.

    Source IS

    3685:1993 E)

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    TO measure the tool wear, the m ajor cutting edges is divide into four zones.

    Zone is the curved part of the cutting edge at the tool corner.

    Zone B is the remaining straight part of the cutting edge between zone

    and zone

    A.

    Zone is the quarter of the worn cutting edge length b farthest away from

    the tool corner.

    Zone

    N

    extends beyond the area of mutual contact between the tool and

    workpiece for approximately lm m to 2mm along the major cutting edge. T he

    wear is of notch wear.

    The width of the flank wear land

    VBB

    shall be measured within zone B

    in

    the tool

    cutting edge plane

    P

    perpendicular to the major cutting edge and from the position

    of the original major cutting edge. The crater depth KT shall be measured as the

    maximum distance between the cra ter bottom and the original face in zone B

    2 5

    Work

    Material

    According to American Iron and Stee l Institute AISI), D2 steel is a high-carbon,

    high-chromium tool steel alloyed with molybdenum and vanadium characterized by.

    High wear resistance

    High compressive strength

    Good through-hardening properties

    High stability in hardening

    Good resistance to tempering-back

    From the characteristics of the steel listed above, it can be suggested that AISI D2

    steel is not one of the easy to machine work material. This is good for the study

    because this study focuses on tool wear that resulted from turning operation. Using

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    N s I D2 steel tool wear can be generated on the inserts with minimal machin ing

    time. Figure 2 9 shows AISI D2 steel work m aterial.

    The

    Table

    Figure 2 9: AISI D2 steel work material

    3mposition of the AISI

    D2

    steel is shown in T able

    2 1

    below.

    2 1:

    AISI

    D2

    steel composition

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    There are other standards for the code of the AISI D2 steel used around the world.

    The D2 code is based on AISI standard. Even with different code names, they are

    still the same steel. For example, in United Kingdom, they use the code B.S.

    D ~

    while in Germany it is DIN 1.2379.

    ISI D2 steel is one of the most widely used steel in the industry. AISI D2 steel is

    recommended for tools requiring very high wear resistance, combined with m oderate

    toughness (shock-resistance). It can also be supplied in various finishes, including

    the hot-rolled, pre-machined and fine machined condition. Some of the many

    applications of ATSI D2 still can be seen in the list below.

    a) Coining Dies

    b) Cold Extrusion Dies

    c) Thread-Rolling Dies

    d) Crushing Hammers

    e) Gauges and Measuring Tools

    f

    Knurling Tools

    g)

    Dies for molding of ceramics, bricks, tiles, grinding wheels and abrasive

    plastic.

    2 6 Surface Roughness

    Surface roughness can generally be described as the geometric features of the

    surface. Surface roughness is related closely to surface integrity. Surface integrity

    referred more to the properties of the surface like fatigue life and corrosion resistance

    which are strongly influenced by the type of surface produced. According to

    Kalpakjian and Schrnid (2001), the main factors that influence surface roughness are

    as follows.

    a) temperatures generated during processing

    b residual stresses

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    c) metallurgical transformation

    d)

    surface plastic deformation, tearing and cracking

    study done using response surface methodology RSM) on a turning process stated

    that the feed rate was found out to be the dominant factor on the surface roughness,

    but it decreased with decreasing cutting speed, feed rate and depth of cut for these

    tools. Sahin Motorcu 2007).

    2 6 1 Surface Roughness Measurement

    There are two most common surface roughness measurement that are arithmetic

    mean value R,) and root-mean-square average Rg ) , both can be calculated using

    Equation 2.1 and 2.2 below respectively.

    The datum line is placed at the center of the graph so that the sum of the area above

    and below the line is equal Figure 2.10.

    Digitized data

    I

    urface profile enter datum) line

    Figure 2.10: Coordinates for surface roughness measurement

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    Surface roughness measuring instrum ents used are called surface profilometers. The

    instrument will measure and recode the surface roughness. The most co-only used

    are the ones using diamond as the stylus. The stylus will travel in a straight line on

    contact with the surface to be measured Figure 2.11.

    Figure 2.11: a) measuring with stylus. @ path of the stylus

    2 7

    esign

    of

    Experiment

    Design of Experiment DOE) can be defined as a structured, organized method for

    determining the relationship between factors affecting a process and the output of

    that process NIST 2006). DOE can also be described as a methods and tools to plan

    and run a series of experiments. The objective of DOE is to determine the variables

    in a process that are the critical param eters and their target values Besterfield 2004).

    It is a method by which purposeful changes is made to the input factors of the

    process in order to observe the effects on the output.

    DOE uses statistical methods to analyze the data achieved to come up with a result.

    By using formal experimental techniques, the effect of many variables can be studied

    at one time Besterfield 2004). There are several me thods can be used as design of

    experiments namely Taguchi methods, Full Factorial, Fractional Factorial, Failure

    Mode and Effect Analysis FMEA ) and Response Surface Methods RSM).

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    2.7.1 Response Surface ethodology

    Response Surface Methodology RSM ) is a set of techniques designed to find the

    best value of a designed response. There are times when using methods other than

    RSM,

    the best value of the values of the response cannot be obtained. This is when

    RSM comes into play. n important aspect of RSM is the Central Composite Design

    CCD). CCD is very useful for building a second order or quadratic model for the

    response variable without needing to use a complete three-level factorial experiment

    NIST 2006).

    Design E xpert software is used to define experimental matrix. The experiment will

    be done using predetermined settings and improvement and optimization will be

    done afterwards. For every input parameter for the experiment, the minimum and

    maximum value is determined on the software and the software will produce a series

    of matrix for the experiment. The experim ent will be done based on this matrix.

    Linear regression is used in RSM to predict experimental input and output

    relationship. Three major analyses to be carried out are the main factor, interaction

    and ANOVA.

    According to NISTISEMATECH, the advantages of RSM are as follows.

    a)

    Simplified equation representing a complex system

    b) Sensitivities are easily obtained

    c) Optimization is easily obtained

    d) Rapid and efficient

    e)

    The use of RSM allows for bringing more knowledge earlier in the design

    process

    f

    Enabling technique for Advanced Design approaches

    g) Instantaneous evaluations

    The use of RSM and DOE along with the methods for running the whole study is

    discussed on the next chapter.

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    CHAPTER

    3

    METHO OLOGY

    2 1 Overview

    This chapter covers the methods for running and com pleting the whole project Every

    detail on the project and how to run the experiment is included also From the type of

    material and obtain ing the result to analyzing and finalizing the report Every step to

    be gone through is also featured in this chapter The flow and sequence of the whole

    project can be seen in Figure 3 1

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    We Sele

    Litc

    srature

    Machin

    ng

    Measure

    . . .

    IQCIZ

    rouahn

    /

    lank.

    nput Dal

    3ta Anal

    rs s

    -it Sumn

    nary

    ectionode1 sell

    Significant .... . .

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    1 N-iit significant Lack of Fit

    int main

    interactic

    factors

    3ns

    and

    timizatio

    4

    a 2 ,

    igure

    3 1:

    Project flowchart

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    3 2 Literature Review

    Literature review requires reviewing of other previous published works that could be

    related to the study or that have useful information to be used in the study. It includes

    gathering of information from books and resources from the internet. In literature

    review, the information and theory regarding the experiment and the machining

    process which is single point turning is defined. The inputs for the experiment is the

    three machining parameter that are cutting speed, feed rate and depth of cut. As for

    the output responses from the machining process, there are two responses to be

    considered that are tool wear and surface roughness. To be able to obtain the result

    from experiment, it is essential

    to know how to measure them. There are certain

    equipments to be used for measuring them that will be discussed later on in this

    chapter. Only then the analysis from the result can be m ade using R esponse Surface

    Methodology RSM).

    3 3 Experiment

    3 3 1

    Machining Param eters Settings

    The experiment will carried out using the RSM approach. The experimental matrix is

    defined using Design Expert 7 This software requires range of experiment input to

    be keyed into it and then the software will suggest the best experiment design to be

    carried out. The inputs for this experiment are cutting speed, feed rate and depth of

    cut. The parameters chosen are based on previous study by Mohd Razali et al.

    2002). The ranges for each of them are as follows.

    Cutting speed

    Depth of cut

    Feed rate

    200 00 m/min

    0.2

    0 5

    rn

    0.3

    0 5

    rnm/rev

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    33 2 Experimental Design

    The experimental design Was based On Cen tral Composite Design CCD). The

    factors for the experiment which are the parameters are keyed into Design Expert

    and the experiment matrix will be obtained as in Table 3 1 The experiment is

    consists of 8 factorial points, 6 axial points and 6 center points.

    Table 3 1: Experimen t matrix extractedfrom esignExpert 7

    There are two responses that are collected from the experiment that are as follows.

    Response Flank wear pm

    Response Surface Roughness pm

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    3 3 3 Tool and Work Material

    The experiment was conducted in accordance to I S 0 3685:1993(E). The cutting tool

    inserts to be used for the machining process are HSS insert (IS 0 SPGN 120308) with

    TiN-coatings and manufactured by Sumitom0 Electric Hardmetal. The tool holder

    used is (FTllR-44A) which is manufactured by Sumitomo Hardmetal. The work

    piece used for machining is AlSI D2 X155CrVMo 12 1 The specification and

    composition can be seen in Table 3.2 and 3.3.

    Table 3.2: Material specifications

    Table 3.3: W ork material chemical com position

    Material

    Insert: HSS IS0 SPGN 120308

    Coating: PVD TiN-coating

    Manufacturer: Kennametal

    Work material: KRUPP

    2379 XI55 CrVMo 12 1

    Element Com osition

    Mo 0.1

    Specifications

    cutting edge length = 12.7mm

    0 d

    =

    12.7mm

    thickness s

    =

    3.1 8mm

    AlSl 0 2 steel dia.

    =

    100mm

    length

    =

    250mm

    3 3 3 quipments

    Single point turning was selected as the machining operation and the machining

    process was done using HAAS CN C lathe machine. Figure 3.2 shows the machining

    process running. The model number for the machine is S L 20T. All experiment was

    done using this machine. The machining process was done without the use of coolant

    (dry machining). For the response from the experiment, there were two measuring

    equipments used. The tool wear w as measured using Toolmaker s Microscope,

    model number Axioskop 40 and manufactured by Ze iss Carl. For surface roughness,