v
TABLE OF CONTENT
Abstract i
Abstrak ii
Dedication iii
Acknowledgment iv
Table of Contents v
List of tables viii
List of figures ix
List of Abbreviations, Symbols and Nomenclature xi
CHAPTER 1: INTRODUCTION
1.1 Background of Project 1
1.2 Problem Statement 2
1.3 Objective Project 3
1.4 Scope of Project 3
CHAPTER 2: LITERATURE REVIEW 5
2.1 Classification of Machining Process
5 2.2 Advanced Machining Thermal Energy Processes
6 2.3
Plasma Assisted Machining 6
2.4 Milling Machine 8
2.4.1 CNC Milling Machine 8
2.4.2 Milling Parameter 9
2.5 Plasma Cutting
10 2.6 Plasma Cutting Parameter
11 2.6.1 Air Pressure
11 2.6.2 Cutting Current
12 2.6.3 Cutting Speed
12 2.6.4 Standoff Distance
12
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2.7 Factor Affecting Plasma Cutting Process
13 2.8 Effect of Temperature on Properties of Material
14 2.9
Metallurgical and Heat Considerations in Thermal Cutting 15
2.10 Surface Integrity 15
2.11 Surfaces 17
2.12 Surface Alteration 18
2.13 Metallurgical Alteration 18
2.14 Heat Affected Zone 19
2.15 Subsurface Microstructure Alteration 20
2.16 Changes in Microhardness 20
2.17 Tool Steel 21
2.17.1 Classification of Tool Steel 2.17.2 Cold Work AISI D2
23 2.17.3 Composition of AISI D2 Tool Steel
23 2.17.4 Previous Work on the Microstructural Analysis of D2 Tool Steel 24
CHAPTER 3: METHODOLOGY 25
3.1 Project Planning 25
3.2 Work Material
27 3.3
Cutting Condition 28
3.3.1 Input Parameter 28
3.3.2 Response Parameter 28
3.4 Experimental Procedure
29 3.4.1 Machining by Using Air Plasma Cutting
29 3.4.2 Sample Preparation
30 3.4.2.1 Machining by using EDM Wire Cut
30 3.4.2.2 Hot Mounting
31 3.4.2.3 Grinding and Polishing
32 3.4.2.4 Etching
34 3.5
Surface Integrity Evaluation 34
3.6 Microhardness Test
35
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CHAPTER 4 : RESULT AND DISCUSSION 36
4.1 SEM Microstructure Images and Observations
37 4.1.1 Subsurface Microstructure of AISI D2
53 4.1.2 Microstructure of AISI D2 before Plasma Cutting
53 4.1.3 Prediction of Microstructure of AIDI D2 after Plasma Cutting
54 4.1.4 Grain Growth
55 4.2
Thickness of Heat Affected Zone 56
4.2.1 Effect of Current 58
4.2.2 Effect of Feed Rate 58
4.2.3 Effect of Air Pressure 58
4.2.4 Effect of Secondary Thermal Based Processing 59
4.3 Microhardness
59
CHAPTER 5: CONCLUSION AND FUTURE WORK 62
