v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgements iv
Table of Content v
List of Tables viii
List of Figures ix
List Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1: INTRODUCTION
1.1 Background
1 1.2 Problem Statements
3 1.3
Objective 4
1.4 Scope of Project
5
CHAPTER 2: LITERATURE REVIEW
2.1 Machining
6 2.1.1 Machinability of Various Other Metals
8 2.1.2 Milling Operation
9 2.1.2.1 Classifications of Milling Processes
9 2.1.3 CNC Milling Machine
11 2.1.4 End Milling Cutters
12 2.2 Cast Iron
13 2.2.1 Gray Cast Iron
14 2.2.1.1 FC300 Gray Cast Iron
15 2.2.2 Ductile Iron Nodular Iron
18 2.2.3 White Cast Iron
18 2.2.4 Malleable Iron
19 2.2.5 Compacted Graphite Iron
20 2.3
Cutting tool 20
vi 2.3.1 Carbides
20 2.3.1.1 Classification of Carbide Tools
21 2.3.2 Cutting Parameter
23 2.3.2.1 Cutting Speed
23 2.3.2.2 Feed Rate
23 2.3.2.3 Depth of Cut
24 2.4
Surface Integrity 24
2.4.1 Surface Profile 26
2.4.2 Surface Roughness 26
2.4.2.1 Roughness Average Parameter R
a
27 2.4.2.2 Effects of Various Parameters on Surface
Roughness 28
2.4.3 Built-Up-Edge BUE 28
2.4.4 Subsurface Microstructure Alteration 29
2.5 Surface Defects
31 2.6
Techniques for Testing Surface Structure 32
CHAPTER 3: METHODOLOGY
3.1 Project Planning
34 3.2
Work Material 36
3.3 Cutting Tool 37
3.4 Cutting Condition
38 3.5
Machine and Equipment 39
3.6 Experimental Procedure
39 3.6.1 Machining by Using 3 Axis CNC Vertical Milling
Machine 39
3.6.2 Testing by Using Surface Roughness Tester 40
3.6.3 Machining by Using Wire Cut Electrical Discharge Machining WEDM
40
3.6.4 Surface Profile Evaluation by Using Scanning Electron Microscope SEM
41
3.6.5 Specimen Preparation for Investigation of Subsurface Microstructure
42
vii 3.6.5.1 Mounting
42 3.6.5.2 Grinding, Polishing and Etching
43
CHAPTER 4: RESULT AND DISCUSSION
4.1 Surface Roughness
48 4.1.1 Effect of Cutting Parameter on Surface Roughness
48 4.2
Surface Profile 53
4.2.1 Effect of Cutting Parameter on Surface Profile 53
4.3 Subsurface Microstructure
58 4.3.1 Effect of Cutting Parameter on Subsurface
Microstructure 58
4.3.1.1 Expected Plastic Deformation 62
4.3.1.2 Expected White Layer Formation 64
CHAPTER 5: CONCLUSION AND RECOMMENDATIONS
