v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Table viii
List of Figure ix
List of Abbreviations xi
CHAPTER 1: INTDOCUTION 1
1.0 Introduction
1 1.1
Objective 3
1.2 Problem Statement
4
CHAPTER 2: LITERATURE REVIEW 5
2.1 Machining
5 2.1.1 Factor That Influence Machining
7 2.1.2 Milling
9 2.1.2.1 Type of Milling Machine
10 2.1.2.2 Equipment for Milling Machine
12 2.1.2.3 Milling Operation
13 2.1.2.4 Feature of Milling Tool
15 2.1.2.5 Type of Milling Tool
17 2.2
Cast Iron 19
2.2.1 History of Cast Iron 19
2.2.2 Production of Cast Iron 20
2.2.3 Properties of Cast Iron 20
vi
2.2.3.1 Tensile Strength 20
2.2.3.2 High Compressive Strength 21
2.2.3.3 Low Melting Point 21
2.2.3.4 Resistance to Deformation 21
2.2.3.5 Resistance to Oxidation 21
2.2.4 Class of Cast Iron 22
2.2.4.1 Gray Cast Iron 22
2.2.4.2 White Cast Iron 23
2.2.4.3 Ductile Cast Iron 24
2.2.4.4 Malleable Cast Iron 25
2.2.4.5 Compacted Graphite Iron 26
2.2.5 FC300 Cast Iron 26
2.2.5.1 FC300 Composition 27
2.3 Surface Integrity
27 2.3.1 Surface Roughness
28 2.3.2 Surface Defect
29 2.4
Cutting Tool 33
2.4.1 General Characteristic of Cutting tool Material 36
CHAPTER 3: METHODOLOGY 42
3.1 Introduction
42 3.2
Flow Chart 43
3.3 Work Material
44 3.4
Cutting Tool 45
3.5 Machining and Cutting
47 3.5.1 Machine Experiment
47 3.5.2 Cutting Parameter
48 3.6
Performance Measure 48
3.6.1 Surface Roughness Tester 48
3.6.2 Surface Profile SEM 49
3.7 Experiment Procedure
50
vii
CHAPTER 4: RESULTS AND ANALYSIS 53
4.1 Surface Roughness, Ra
53 4.1.1 Optimization Surface Roughness
59 4.2
Surface Profile 63
4.2.1 Surface Profile for Each Cutting Parameter 65
CHAPTER 5: CONCLUSION AND RECOMMENDATION 68
5.1 Conclusion
68 5.2
Recommendation 70
REFERENCES 71
viii
LIST OF TABLE
2.1 Different Between Orthogonal and Oblique Machining
6 2.2
Factors Influence Machine Operation 8
2.3 Equipment for Milling Machine
12 2.4
Milling Operation 13
2.5 Feature of Milling
15 2.6
Milling Cutter 17
2.7 Range of Composition for Cast Iron
22 2.8
General composition FC300 27
2.9 General Characteristic of Cutting Tools
36
3.1 Chemical Composition of FC300 Cast Iron
44 3.2
Specification Parameter of Ball End Mill Hitachi ABPF-32MT4 45
3.3 Experiment Procedure
50
4.1 Results for Surface Roughness for Each Parameter and Average
53 4.2
ANOVA Table for Response Surface Cubic Model 55
4.3 SEM Image for Surface Profile
66
ix
LIST OF FIGURE
2.1 Orthogonal Machining and Oblique Machining
6 2.2
Milling Machine 9
2.3 Column and Knee Type Milling Machine
10 2.4
Bed Type Milling Machine 11
2.5 CNC Milling Machine
11 2.6
Diagram of an End Mill Cutting Tool 16
2.7 Metal Alloy Classification
19 2.8
Microstructure for Gray Cast Irons with Graphite Flakes 23
2.9 Microstructure for White Cast Iron
24 2.10
Microstructure for Ferrictic Ductile Cast Iron 24
2.11 Microstructure for Pearlitic Malleable Ductile Cast Iron
25 2.12
Coordinate uses for surface roughness measurement 29
2.13 Standard Terminology and Symbols to Describe Surface Finish
29 2.14
Cracks 30
2.15 Craters
30 2.16
The Interaction between Heat Source and the Base Metal 31
2.17 Intergranular Attack
31 2.18
Pits 32
2.19 Single Point Cutting Tool for Turning Application
33 2.20
Multipoint Cutting Tool 34
2.21 The Hardness of Various Cutting Tool Materials
35 2.22
Mechanical Properties for Groups of Tool Materials 36
3.1 Research Methodology
43 3.2
The Main Grey Cast Iron Grades Worldwide 44
3.3 Ball End Mill 32mm Hitachi ABPF-32 MT4
45 3.4
Insert for Ball End Mill 32mm 46
x
3.5 Specifictaion Parameter of Insert SRFT 30 VP15TF
46 3.6
DMF 250 Linear Deckel Maho 47
3.7 Surface Roughness Tester
48 3.8
Scanning Electron Microscope 49
4.1 Annova Evaluation Graph
56 4.2
Comparison between Actual Values and Calculated Value 58
4.3 Influence of Spindle Speed over Ra
59 4.4
Influence of Feed Rate over Ra 60
4.5 Response Surface Interaction between Spindle Speed and Feed Rate
61 4.6
Contour of Minimum Region of Surface Roughness 62
4.7 Porosity Occur at Surface FC300 Cast Iron
63 4.8
Propagation of Crack 64
4.9 Flaking at Surface FC300 Cast Iron
64 4.10
Surface Roughness and Surface Profile at Good Region 67
xi
LIST OF ABBREVIATIONS
Anova -
Analysis of Variance Cbn
- Cubic Boron Nitride
CNC -
Computer Numerical Method EDM
- Electric Discharge Machine
HSM -
High Speed Machine HSS
- High Speed Spindle
MMSB -
Miyazu Malaysia Sdn Bhd MRR
- Material Removal Rate
Ra -
Arithmetic Average SEM
- Scanning Electron Microscope
Rpm -
Revolution per Minute UTeM
- Universiti Teknikal Malaysia Melaka
1
CHAPTER 1 INTRODUCTION
