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TABLE OF CONTENT
Abstract i
Abstrak ii
Acknowledgement iii
Dedication iv
Table of content v
List of figure ix
List of table xi
List Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1.0 : INTRODUCTION 1
1.1 Background
6
1.2 Objective
6
1.3 Scope of Project
7 1.4
Problem Statement 8
1.5 Outline of report
8
CHAPTER 2.0 : LITERATUTURE REVIEW
2.1 Drilling
10 2.2
CNC Machining centre 12
2.3 Cutting tool
15
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2.3.1 Solid Carbide 16
2.3.2 Special Solid Carbide Tools 17
2.3.3 Carbides uncoated tool 18
2.3.4 Coated carbide coated tool 18
2.3.5 High Speed Steel Drill HSS 19
2.4 Tool holder For Drills
21 2.5
Causes of Drill Failure 22
2.6 Aluminum alloy
23 2.6.1 Machining of aluminum alloys
23 2.6.2 Alloy elements
24 2.6.3 Important when machining aluminum alloys
24 2.6.4 Practical use
24 2.7
Intelligent parameter selection 25
2.7.1 Cutting speed 25
2.7.2 Feed rate 27
2.7.3 Tool Length 28
2.7.4 Hole depth 29
2.7.5 Machines Vibration 30
2.7.6 Hole diameter accuracy 32
2.8 Mathematical model
34 2.8.1 Accelerometer
34 2.8.2 Linear Regression
35 2.8.3 Vibration
36
CHAPTER 3.0 : METHODOLOGY 38
3.1 Introduction
38 3.2
Procedure of Project 41
3.3 Procedures of experiment
41 3.3.1 Objective
41 3.3.2 Determining process variables
42
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3.3.2.1 Cutting speed 43
3.3.2.2 Feed Rate 44
3.3.2.3 Tool Length 45
3.3.2.4 Work piece and insert 46
3.3.2.5 Vibrations 46
3.3.2.6 Final dimension of sample of work piece 47
3.4 Table matrix design 47
3.5 Data Acquisition 48
3.5.1 Accelerometer 48
3.5.2 CNC machining centre 50
3.5.3 Experimental setup 51
. 3.5.4 Sample measurement 53
CHAPTER 4.0 : RESULT AND DISCUSION
4.1 Result 54
4.1.1 Sampling Data Structure 55
4.1.2 Drilling Operation 56
4.1.3 Experimental Results 59
4.2 Discussion 61
4.2.1 Hole diameter Accuracy measurement 61
4.2.2 Vibrations collections 62
4.2.3 Main effect plot 64
4.2.4 Multiple regression modeling 65
4.2.5 Regression Analysis for x-axis 66
4.2.6 Best subsets for constructing best model for x-axis 67
4.2.7 Constructing Best Model for X-axis 68
4.2.8 Multiple regression modeling for y-axis 69
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4.2.9 Regression analysis for y-axis 70
4.2.10 Best subsets for constructing best model for x-axis 71
4.2.11 Constructing Best Model for Y-axis 72
4.2.12 Residual plots For x-axis 73
4.2.13 Normal Probability Plot for Hole Diameter 74
4.2.14 Histogram 74
4.2.15 Residual plot versus order 75
4.2.16 Normal Probability Plot for Hole Diameter 76
4.2.17 Residual plots versus fitted values 76
4.2.18 Histogram 76
4.2.19 Residual plot versus order 77
4.3 Model Validation 77
4.3.1 Unpaired Test for x-axis 77
4.3.2 Null Hypothesis x-axis 79
4.3.3 Unpaired Test for y-axis 80
4.3.4 Null hypothesis y-axis 82
CHAPTER 5.0 : CONCLUSION AND RECOMENDATION
