viii
TABLE OF CONTENTS
Declaration
ii Approval
iii Abstract
iv Abstrak
v Dedication
vi Acknowledgement
vii Table of Contents
viii List of Figures
iv List of Tables
v List of Abbreviations, Signs, and Symbols
vi
CHAPTER 1: INTRODUCTION 1
1.1 Background of Project
1 1.2
Problems Statements 6
1.3 Objectives of Project
7 1.4
Scope of Project 7
1.5 Report Outline
8 1.6
Gantt Chart 9
CHAPTER 2: LITERATURE REVIEW 11
2.1 Introduction
11 2.2
Machining Process 13
2.2.1 Type of Metal Cutting 12
2.2.1.1 Types of Production 14
2.2.2 CNC Lathe Machine 15
2.2.3 Automatic Tool Changers 15
2.2.4 Manual Tool Changing 16
ix 2.3
Cutting Tool Material 16
2.3.1 Carbide Inserts Turning 17
2.4 Machining Parameters
17 2.4.1 Cutting Speed
17 2.4.2 Feed Rate
18 2.4.3 Depth of Cut
19 2.5
Surface Roughness 22
2.5.1 Introduction of Surface Metrology 24
2.5.2 Roughness 25
2.5.3 Waviness 25
2.5.4 Method to Analyze Surface Roughness 25
2.5.4.1 Average Roughness R
a
25 2.6
Cutting Fluids 27
2.6.1 Functions of Cutting Fluids 27
2.7 Taguchi’s Method
28 2.8
Prediction the Result by Pass Research about the Surface Integrity 30
CHAPTER 3: METHODOLOGY 32
3.1 Introduction
32 3.2
Planning 33
3.3 Selection of Machine and Equipment
33 3.3.1 Selection of Machine
33 3.3.1.1 CNC Lathe Machine
33 3.4
Selection of Workpiece Material 36
3.4.1 Mild Steel 36
3.5 Selection of method for Analysis
38 3.5.1 Method to Analyze Surface Roughness
38 3.5.2 Surface Roughness Measurement
40 3.5.3 Surface Roughness Tester SJ-301 Procedure
41
x 3.6
Experiment Procedure 41
3.6.1 Experimental Design 41
3.6.2 Cutting Parameters 42
3.6.3 Experiment Flowchart 44
3.7 Lab Sheet Design
45
CHAPTER 4: RESULTS AND ANALYSIS 46
4.1 Introduction
46 4.2
Design of Experiment 47
4.3 Findings and Data Analysis of Surface Roughness
48 4.3.1 Interaction Plot for SN ratios Feed Rate
49 4.3.2 Interaction Plots for SN ratios Depth of Cut
50 4.3.3 Effect of Control Parameters on Surface Roughness
51 4.3.4 ANOVA Table for response function of the surface roughness
54 4.4
Predicted Result at Optimum Setting Condition 55
4.4.1 Confirmation Test 55
4.4.2 Comparison Test Result 56
CHAPTER 5: DISCUSSION 57
5.1 Introduction
57 5.2
Machining Parameter Analysis 58
5.3 Surface Roughness Analysis
58 5.3.1 Feed Rate
59 5.3.2 Cutting Speed
59 5.3.3 Depth of Cut
60 5.3.4 Other Factors
61
CHAPTER 6: CONCLUSION AND RECOMMENDATION 62
