v
TABLE OF CONTENT
Abstrak
i Abstract
ii Dedication
iii Acknowledgement
iv Table of Content
v List of Tables
viii List of Figures
ix List Abbreviations, Symbols and Nomenclatures
xi
CHAPTER 1: INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 3
1.3 Objectives 3
1.4 Scope of Study 4
1.5
Organization of Final Project 4
1.6
Summary 5
CHAPTER 2: LITERATURE REVIEW 6
2.1 Introduction
6 2.2
Drilling Machine Operation 7
2.2.1 Types of Drilling Machine 8
2.2.2 Types of Drill 10
2.2.3 Drilling Characteristics 12
2.3 CNC Vertical Milling Machine
12 2.4
Process Parameters 13
2.4.1 Spindle Speed 13
2.4.2 Drill Diameter 14
2.4.3 Feed Sending Speed 14
2.5 Drilling Characteristics
15 2.5.1 Surface Integrity
15
vi 2.5.2 Material Removal Rate
16 2.5.3 Surface Roughness
16 2.6
Material Workpiece 17
2.7 Design of Experiment
18 2.7.1 Response Surface Method RSM
19 2.7.2 Central Composite Design CCD
20 2.7.3 Analysis of Variance ANOVA
20 2.8
Review on Drilling Research 20
CHAPTER 3: METHODOLOGY 23
3.1 Introduction
23 3.2
Research Planning 23
3.2.1 Flowchart 24
3.3 Specimen Preparation
25 3.4
Tool Preparation 27
3.5 Machine and Measurement Equipment
27 3.5.1 Band Saw
27 3.5.2 Conventional Milling Machine
28 3.5.3 CNC Vertical Milling Machine
29 3.5.4 Portable Surface Roughness Tester
29 3.5.5 Portable Microscope
30 3.5.6 Mettle Teldo Machine
30 3.6
Experimental Setup 31
3.6.1 Experimental Matrix 32
3.7 Design of Experiment DOE
33 3.7.1 Response Surface Method using Minitab 17 Statistical Software 33
CHAPTER 4: RESULT DISCUSSION 36
4.1 Experimental Matrix
36 4.2
Experimental Result 38
4.3 Analysis of the Result
42 4.3.1 Analysis Result of Material Removal Rate
42 4.3.1.1 Analysis of Variance ANOVA
42
vii 4.3.1.2 Main Effect Plot for Material Removal Rate
44 4.3.1.3 Surface Plot for Material Removal Rate
45 4.3.1.4 Interaction Plot for Material Removal Rate
46 4.3.1.3 Regression Equation for MRR
46 4.3.2 Analysis Result of Surface Roughness
47 4.3.2.1 Analysis of Variance ANOVA
47 4.3.2.2 Main Effect Plot for Surface Roughness
48 4.3.2.3 Surface Plot for Surface Roughness
49 4.3.2.4 Interaction Plot for Surface Roughness
50 4.3.2.3 Regression Equation for Surface Roughness
50 4.3.3 Surface Appearance
51 4.3.3.1 Surface Appearance of Minimum Surface Roughness
51 4.3.3.2 Surface Appearance of Maximum Surface Roughness
52 4.4
Response Optimisation 53
4.4 Discussion
54
CHAPTER 5: CONCLUSION RECOMMENDATIOS 55
