v 2.3.1 The Basic Parts of Lathe Machine
8 2.3.2 Type Of Lathe
11 2.3.3 Computer Numerical Control CNC Lathes
12 2.3.4 Operations Performed In a Center Lathe
13 2.3.4.1 Boring
13 2.3.4.2 Facing
14 2.3.4.3 Threading
15 2.3.4.4 Drilling
15 2.3.4.5 Knurling
16
2.4 Cutting Tools In Turning 16
2.4.1 Type of metal cutting 17
2.4.2 Cutting Geometry 17
2.4.3 Cutting Tool Material 22
2.4.4 Requirements Of Tool Materials 22
2.4.5 Type Tool Materials 23
2.4.5.1 High-speed steel HSS 23
2.4.5.2 Cast Cobalt Alloys 24
2.4.5.3 Cemented Carbide 24
2.4.5.4 Diamond 24
2.4.5.5 Ceramics 25
2.4.5.6 Cubic Boron Nitride 25
2.4.6 Coating Materials of Cutting Tools 25
2.4.6.1 Titanium nitride TiN 26
2.4.6.2 Aluminum OxideAl
2
O
3
26 2.4.6.3 Titanium aluminum nitride TiAlN
26 2.4.7 Tool Coating Processes
27 2.4.7.1 Chemical vapor deposition CVD
27 2.4.7.2 Physical Vapor Deposition PVD
28
vi
2.5 Surface Integrity 28
2.5.1 Surface finish 31
2.5.1.1 Surface finish symbols 32
2.5.2 Surface Roughness 34
2.5.2.1 Surface Roughness Measurement 35
2.5.2.2 Surface Roughness Measuring Method 39
2.5.2.3 Surface Roughness Measuring Calculation 44
CHAPTER III METHODOLOGY
46
3.1 Machine Use For Machining 46
3.1.1 Conventional Lathe Machine 46
3.1.2 Computer Numerical Control CNC Turning Machine 47
3
.2 Selection Of The Work Material 49
3.3 Selection Of Cutting Tool 50
3.4 Centre Drill And Pre -Machining Operation Procedure 51
3.4.1 Centre drill procedure 51
3.4.2 Pre machining operation procedure 53
3.5.1 Cutting speed 54
3.5.2 Cutting time 54
3.5.3 Depth of cut 55
3.5.4 Feed rate 55
3.6 Machining Operation Procedure 55
3.7 NC Code Use In The Machining 58
3.8 Experiment Analysis Method 59
3.8.1 Portable Surface Roughness Tester, SJ-301 59
3.8.1.1 Procedure 60
3.8.2 SEM Operating Parameters 61
3.8.2.1 Sequence To Operation Of The SEM 62
3.8.3 Metallurgy Microscope Operating Parameters 63
3.9 Experimental Apparatus 65
vii 3.10 Experiment Procedure Flow Chart
66
CHAPTER IV RESULT
67
4.1 Introduction 67
4.2 Effect of MachiningCutting Time, T 67
4.3 Tool Wear Effect on Surface 69
4.4 Effect of Cutting Speed on Surface Profile 71
CHAPTER V DISCUSSION
75
5.1 Relationships between the surface roughness and the flank wear 75
5.2 Factors influence the surface integrity 77
5.3 Surface defects on the material after high speed machining 78
5.3.1 None continues waves on surface
78 5.3.2 Plastic deformation
80 5.3.3 Tool deposit
82
CHAPTER VI CONCLUSION
83
6.1 Conclusion 83
6.2 Recommendation 84
REFERENCES 85
viii
LIST OF FIGURES
Figure 2.1 Schematic illustration of the basic principle of the turning
operation 8
Figure 2.2 Conventional Lathe Machine Available At UTeM
9 Figure 2.3
Boring Operation 14
Figure 2.4 Facing Operation
14 Figure 2.5
Threading Operation 15
Figure 2.6 Drilling Operation
16 Figure 2.7
Nomenclature of a general-purpose lathe toolbit 18
Figure 2.8 Cutting Tool Geometry
19 Figure 2.9
Coated Cutting Tools 27
Figure 2.10 Surface Integrity Definitions 31
Figure 2.11 Surface Finish Symbols 33
Figure 2.12 Surface Texture Symbols 34
Figure 2.13 a Surface Produced b Cross Section through Surface
Irregularities 37
Figure 2.14 Basic Characteristics Of Surface Roughness Measurement
ASME standard B46.1, 1995 38
Figure 2.15 Effect of Cutting Speed on the Surface Roughness of
Turned Specimens of Mild Stee 38
Figure 2.16 Comparison of Experimental Results with an Idealized 38
