CHAPTER 3
METHODOLOGY
3.1 INTRODUCTION
This section contains the procedures and method to achieve the objective of this research. The chapter is to ensure that the project is following the time that is given to
complete this research. The equipment and machine that will be used to carry out this project will be explained, and also the material parameters will be outlined.
The quality of a milling surface is a key to investigate the effect of machining parameters on surface morphology. The parameters of the machine include cutting
speed, feed rate, radial deep of cut and axial deep of cut will be analyzed in order to compare different result of varying parameters. The material work piece is AISI D2
tool steel with hardness of 63 HRc was used in experiment for determining the surface
finish at the end of machining. The end milling operation was conducted using a 20mm diameter tool fitted with one flute inserts. The cutting tool is coated using physical
vapour disposition PVD TiAlN with the code of APKT 100308 PDER-X PH 6920, supply by PALBIT cutting tools manufacture. End mill process is performed flooded
coolant system. Machining process was conducted on 3-axis CNC milling machine of model HAAS VF-10.
There are several other aspects that should be considered in achieving the objective of this experiment is:
1. Different machining parameter that need to tested 2. Work piece material that will used
3. Tool quality
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4. Type of machine capability of machine 5. Method used to analyze the result in the experiment
3.2 PROCESS FLOW CHART
STAR T
PROBLEM IDENTIFICATION
LIBRARY RESEARCH
PARAMETER SET
DESIGN OF EXPERIMENT
MACHINING
DATA COLLECTION
MODELING
OPTIMIZATION ESTIMATE ERROR
VALIDATION
EN D
NO
YES
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3.3 WORKPIECE MATERIAL
The work piece material selected for this experiment is D2 tool steel, the figure 3.1. This material widely used in aerospace application. Apart from that, it is also used in
tool die making. According to Hamidzadeh et al. 2012 AISI D2 tool steel and belong other group D of cold work tool steels that are high carbon- and high chromium-
contained steels which used broadly in machining and manufacturing applications. High carbon steel also belongs to D2 tool steel group. AISI D2 contains high
chromium tool steel alloyed with general properties that are:
• High wear resistance • High compressive strength
• Good through-hardening properties • High stability in hardening
• Good resistance to tempering-back.
Figure 3.1: Material AISI D2 tool steel
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Table 3.1 and table 3.2 are showed the chemical properties of tool steel and the mechanical properties of that material.
Table 3.1: chemical properties of AISI D2 tool steel Hamidzadeh et al., 2012
Element Weight
C Carbon 1.40-1.60
Mn Manganese 0-0.60
Si Silicon 0-0.60
Cr Chromium 11.00-13.00
Ni nickel 0-0.30
Mo Molybdenum 0.70-1.20
V Vanadium 0-1.10
Fe iron 81.6-86.9
Table 3.2: mechanical properties at room temperature Hamidzadeh et al., 2012
Mechanical properties Description
Density ×1000 kgm3 7.62-7.78
Young’s modulus GPa 205-215
Poissons Ratio 0.27-0.30
Yield strength elastic limit ×1000 MPa
1.86-2.29
Tensile strength ×1000 MPa 2.1-2.5
Harness- Rockwell C 58-64
Elastic Modulus GPa 190-210
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3.4 CUTTING PARAMETER SETUP
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