Study The Surface Roughness Of AISI 1045 Carbon Steel By Using Dry CnC Turning.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

STUDY THE SURFACE ROUGHNESS OF AISI 1045 CARBON

STEEL BY USING DRY CNC TURNING

This report is submitted in accordance with the requirement of Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor of Manufacturing Engineering

Technology (Process and Technology) with Honours

NORZARATUL AIN BINTI ISMAIL B071210103

930513-02-5248

FACULTY OF ENGINEERING TECHNOLOGY 2015

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA TAJUK: Study the Surface Roughness of AISI 1045 Carbon Steel by Using Dry CNC Turning

SESI PENGAJIAN: 2015/16 Semester 1

Saya NORZARATUL AIN BINTI ISMAIL

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

__________________________ Alamat Tetap:

NO. 14 Taman Darul Aman, 06000 Jitra,

Kedah.

Disahkan oleh:

__________________________

Cop Rasmi:

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

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DECLARATION

I hereby, declared this report entitled “Study the Surface Roughness of AISI 1045 Carbon Steel by Using Dry CNC Turning” is the results of my own research except

as cited in references.

Signature :………

Name : NORZARATUL AIN BINTI ISMAIL Date : ………

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APPROVAL

This report is submitted to the Faculty of Engineering Technology of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering Technology (Process and Technology) with Honours. The member of the supervisory is as follow:

………. DR. UMAR AL-AMANI BIN HJ. AZLAN

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ABSTRACT

In manufacturing industries, surface quality of machining parts is one of the most customers demand. The major indication of surface quality on machine parts is surface roughness. Therefore, this project presents the experimental investigation for the effect spindle speed and feed rate on the surface roughness of medium carbon steel with series number 1045 (AISI 1045). This experiment was conducted by CNC turning machine mainly focused on dry cutting operation. Type of insert used in the experiment was Carbide insert with three edges of Sanvik Coromant brand with ISO number ZP 352 TNMG 160404-MB. The value of surface roughness, tool wear and chip formation were observed for two different values of feed rate, 0.15 mm/rev and 0.50 mm/rev. The values of spindle speed were 275 mm/min, 325 mm/min, 375 mm/min and 425 mm/min with constant depth of cut of 1 mm. These values were taken within the minimum and maximum value of spindle speed and feed rate that can be referred from the ISO code of Sandvik Coromant carbide insert. A surface roughness tester has been used to measure the surface roughness of the AISI 1045. Meanwhile, the tool wear on the inserts have been observed by using an optical microscope. The chips produced were taken for additional data and discussion of this study. From the analysis, the result showed that the spindle speed and feed rate were influenced the surface roughness of the AISI 1045. The results also showed that tool wear occurred at the carbide inserts with different values at different parameters. This study, will help to understand the effect of spindle speed and feed rate on the surface roughness in dry machining condition and identify the optimum parameters based on the characterization study.

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ABSTRAK

Dalam industri pembuatan, kualiti permukaan bahagian yang dimesin adalah salah satu kehendak utama pelanggan. Petunjuk yang paling penting bagi kualiti sesuatu permukaan yang dimesin ialah kekasaran permukaan. Oleh itu, projek ini membentangkan eksperimen bagi mengkaji kesan putaran per minit dan kadar uluran ke atas kekasan permukaan keluli karbon sederhana yang bernombor siri 1045 (AISI 1045). Eksperimen ini difokuskan untuk dijalankan dalam keadaan kering dengan menggunakan mesin pelarik yang dikawal oleh sistem computer (CNC). Jenis mata alat yang digunakan dalam eksperimen ini ialah mata alat bersadur karbide dari Sandvik Coromant dengan nombor ISO ZP 352 TNMG 160404-MB yang mempunyai tiga penjuru. Nilai kekasaran permukaan, kelusuhan mata alat dan pembentukan cip dilihat untuk dua nilai kadar uluran yang berbeza, 0.15 mm/min dan 0.50 mm/min. Nilai putaran per minit yang digunakan adalah 275 mm/min, 325 mm/min, 375 mm/min dan 425 mm/min dengan kedalaman potong yang dimalarkan sebanyak 1 mm. Nilai-nilai ini diambil di antara nilai minima dan maksima putaran per minit dan kadar uluran yang dapat dirujuk daripada kod ISO mata alat karbide Sandvik Coromant. Sebuah alat penguji kekasaran permukaan telah digunakan untuk mengukur kekasaran permukaan AISI 1045. Sementara itu kelusuhan pada mata alat telah dilihat dengan menggunakan mikroskop optical. Cip yang terhasil juga turut diambil sebagai perbincangan dan data tambahan untuk pembelajaran ini. Daripada analisis yang dibuat, keputusan kajian menunjukkan bahawa nilai putaran per minit dan kadar uluran mempengaruhi kekasaran permukaan AISI 1045. Keputusan juga menunjukkan nila kelusuhan pada mata alat karbide yang terjadi berbeza apabila nilai parameter berbeza. Kajian ini akan membantu untuk memahami dengan lebih mendalam tentang kesan putaran per minit dan kadar uluran ke atas kekasaran permukaan yang dimesin dalam keadaan kering dan membantu untuk mengenalpasti parameter yang optima berdasarkan kajian gambaran sifat yang telah dilakukan.

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DEDICATIONS

This project is specially dedicated to my beloved family, project supervisor and all my friends for being my great pillars of support throughout my journey of education.

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ACKNOWLEDGMENT

I wish to acknowledge and express my gratitude and appreciation to my supervisor, Dr. Umar Al-Amani bin Hj. Azlan for his supervision, encouragement, suggestion and constant support through the research and contribution for the success of this project. My deepest gratitude and special thanks also goes to my beloved parents, Ismail bin Kassim and Siti Maizun bt Sebran, my sister and my brother for their endless love and special support.

Sincere thanks to Mr. Nor Fauzi bin Tamin and Dr. Mohd Hadzley bin Abu Bakar from faculty of Manufacturing Engineering (FKP) for helping me to solve various experiment problems and to finish the project. Besides that, also thanks to every assistant engineers in Faculty of Engineering Technology (FTK) for their cooperation and active involvement.

Last but not least, to all my friends and for those who directly or indirectly contribute in this project, thank you.

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DECLARATION ... iv

APPROVAL ... v

ABSTRACT ... vi

ABSTRAK ... vii

DEDICATIONS ... viii

ACKNOWLEDGMENT ... ix

TABLE OF CONTENTS ... x

LIST OF FIGURES ... xiii

LIST OF TABLES ... xiv

LIST OF SYMBOLS AND ABBREVIATIONS ... xv

CHAPTER 1 ... 16

1.1 Project Background ... 16

1.2 Problem Statement ... 17

1.3 Objective ... 18

1.4 Project Scope ... 18

1.5 Concluding Remarks ... 19

CHAPTER 2 ... 20

2.1 Turning Process ... 20

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2.2 Machining Parameters ... 23

2.2.1 Spindle Speed ... 24

2.2.2 Feed Rate ... 25

2.3 Cutting Tool ... 25

2.3.1 Cutting Tool Material ... 26

2.3.2 Cutting Tool Wear... 27

2.4 Chips Formation ... 28

2.5 Dry Cutting ... 29

2.6 Carbon Steel ... 30

2.6.1 Carbon Steel Properties ... 33

2.6.2 Limitation of Carbon Steel ... 34

2.7 Surface Roughness ... 34

2.7.1 Surface Roughness Parameters ... 35

2.8 Measurement of Surface Roughness ... 36

2.8.1 Surface Roughness Tester ... 36

2.8.2 Optical Microscope ... 37

2.9 Concluding Remarks ... 38

CHAPTER 3 ... 39

3.1 Experimental Design ... 39

3.2 Performing the Experiment ... 39

3.2.1 Material and Cutting Tool Preparation ... 39

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xii

3.3 Parameter Study ... 43

3.3.1 Effect of Different Spindle Speed ... 44

3.3.2 Effect of Different Feed Rate ... 44

3.4 Sample Output Preparation ... 44

3.5 Analysis of Data ... 45

3.5.1 Surface Roughness Tester ... 45

3.5.2 Observation of Tool Wear by Optical Microscope ... 47

3.6 Concluding Remarks ... 48

CHAPTER 4 ... 49

4.1 Surface Roughness ... 49

4.1.1 Surface Roughness Data and Graph Analysis ... 49

4.2 Tool Wear ... 54

4.3 Chips Formation ... 59

4.4 Concluding Remarks ... 62

CHAPTER 5 ... 63

5.1 Conclusion ... 63

5.2 Recommendation ... 64

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LIST OF FIGURES

Figure 1.1: Project flow... 19

Figure 2.1: Conventional turning machine ... 20

Figure 2.2: Turning process ... 21

Figure 2.3: CNC turning machine ... 23

Figure 2.4: Parameters that affect surface roughness... 24

Figure 2.5: Turning cutting insert ... 26

Figure 2.6: Tool wear zone ... 28

Figure 2.7: Type of chips formation ... 29

Figure 2.8: Classification of steel ... 31

Figure 2.9: Cross-section typical surface of roughness average (Ra) ... 36

Figure 2.10: Schematic diagram for stylus tester instrument ... 37

Figure 2.11: Optical microscope ... 38

Figure 3.1: Overall of the experimental design of the project ... 40

Figure 3.2: AISI 1045 Carbon Steel ... 41

Figure 3.3: Carbide insert type ZP352 ... 41

Figure 3.4: Insert holder ... 41

Figure 3.5: Centre drilling process ... 42

Figure 3.6: CNC turning machine DMG Mori Seiki CTX 310 ecoline ... 42

Figure 3.7: Clamped workpiece ... 42

Figure 3.8: Workpiece after turning process ... 45

Figure 3.9: Number of experiment marks on workpiece ... 45

Figure 3.10: Surface roughness tester of Mitutoyo Surftest SJ-401. ... 46

Figure 3.11: The uses of stylus at the contact surface of workpiece... 47

Figure 3.12: Optical microscope in Metrology Laboratory ... 47

Figure 3.13: Observation of tool wears ... 48

Figure 4.1: Ra profile of AISI 1045 carbon steel at feed rate 0.15 mm/rev... 50

Figure 4.2: Ra profile of AISI 1045 carbon steel at feed rate 0.50 mm/rev... 51

Figure 4.3: Surface roughness vs. Spindle speed at feed rate 0.15 mm/rev ... 52

Figure 4.4: Surface roughness vs. Spindle speed at feed rate 0.50 mm/rev ... 53

Figure 4.5: Tool wear vs. Spindle speed at feed rate 0.15 mm/rev ... 55

Figure 4.6: Tool wear vs. Spindle speed at feed rate 0.50 mm/rev ... 56

Figure 4.7: Tool wear on carbide inserts at feed rate 0.15 mm/rev ... 57

Figure 4.8: Tool wear on carbide inserts at feed rate 0.50 mm/rev ... 58

Figure 4.9: Formation of chips at feed rate 0.15 mm/rev... 60

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xiv

LIST OF TABLES

Table 2.1: Composition of plain carbon steel ... 32

Table 3.1: Dry cutting process variables ... 43

Table 3.2: General information of surface roughness tester ... 46

Table 3.3: General information of optical microscope ... 48

Table 4.1: Overall of Ra value of AISI 1045 carbon steel ... 49

Table 4.2: Spindle speed and Surface Roughness, Ra at feed rate 0.15 mm/rev ... 52

Table 4.3: Spindle speed and Surface Roughness, Ra at feed rate 0.50 mm/rev ... 53

Table 4.4: Spindle speed and tool wear value at feed rate 0.15 mm/rev... 55

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LIST OF SYMBOLS AND ABBREVIATIONS

BUE - Build-up Edge

CNC - Computer Numerical Control CAD - Computer Aided Design

CAM - Computer Aided Manufacturing CLDATA - Cutter location data

HSS - High Speed Steel NC - Numerical Control

Ra - Roughness Average

Rq - Root-mean-square roughness

Ry - maximum peak-to-valley roughness height AA - Arithmetic Average

CLA - Center Line Average 3D - Three Dimensional

AISI - American Iron and Steel Institute SS - Stainless Steel

Mpa - Mega Pascal

Rpm - Revolutions per minute

UTeM - Universiti Teknikal Malaysia Melaka

μ - Micron

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CHAPTER 1 INTRODUCTION

1.1 Project Background

Machining is an industrial process in which metal parts are shaped or removed by metal cutting process (Patel et al., 2012). In the metal removal process, the output quality of the machined part is rather important. Turning is one of the widely used and important machining processes in engineering industries (Ahilan et al., 2013). Lathe machine is one of oldest conventional machine tool that still being used in the manufacturing industries to produce cylindrical parts. However, Computer Numerical Control (CNC) turning machine are widely used nowadays as it can produce good quality machined parts, high accuracy and high productivity (Patel et al., 2012).

Turning is machining operation that can be performed on a lathe and widely used in variety manufacturing industries such as automotive and aerospace. In the machining process, quality of surface plays a very important role in the performance of turning. This is because, good quality turned surface is significant in improving quality (Patel et al., 2012). In CNC turning, there are many parameters cutting conditions that will affect the surface roughness of the workpiece. These factors are controllable factors such as feed rate, depth of cut and spindle speed and the uncontrolled factors such as material properties and tool geometry of both tool and workpiece) (Rao et al., 2013).

In general, the surface roughness term are usually used to describe a surface which has been prepared by machining, grinding or other processes. Good surface finish is needed to improve the properties, strength, corrosion resistance and aesthetic appeal of product (Rawangwong et al., 2014). Surface roughness has a factor that

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17 process employed to create the surface.

Although machined surface appear smooth to the naked eye, the surface are quite rough at the microscopic level. In this challenge world, striving for lower cost solution and shorter lead time is the main challenge for industries around the world to maintain their competitiveness. Automated and flexible manufacturing systems are employed for that purpose.

1.2 Problem Statement

Nowadays, the so called surface roughness of the product is a major issue in many industries. The major issue of this factor makes manufacturing engineers faced with the difficulties to increase the productivity (Rawangwong et al., 2014). The demand for high quality products with good surface finish also increase day by day due to the newer applications in various fields such as die and mold manufacturing, automobile and also aircraft industries.

In CNC machining, the optimal parameters and cutting condition under the given machining situation is difficult to determine. The conventional ways to choose the ideal parameters are based upon data from the machining handbooks or from the knowledge of the programmer. Hence, uneven surface roughness is produced because of such conservative machining parameters.

In order to obtain a good quality product and increase the productivity, it is important to optimize the machining parameters. This is because, the surface roughness of a machined part different with the change of cutting process parameters. Optimization of machining parameters usually a difficult work as the knowledge of machining and the aspect of machine tool capabilities are required. Instead of the surface roughness, the scratch marks and inaccuracies in the cut also can be affected.

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lubricant cost and workpiece, and also the tool machine cleaning cycle time. Health problem can be caused by the long term exposure to the cutting fluids and by the inappropriate way while handling with the cutting fluids. Then, the adhesion and friction between tool and chip tend to be higher in dry machining process. These situations will cause higher temperature, higher tool wear rates and consequently, shorter too lives. Therefore, the ideal parameters have to be found in order to achieve the desired surface roughness.

1.3 Objective

The objectives of this project are:

i. To study the effect of spindle speed and feed rate of dry cutting CNC turning on surface roughness of AISI 1045 carbon steel.

ii. To identify the optimum spindle speed and feed rate based on characterization study.

1.4 Project Scope

The scopes of this project are to conduct a machining process which is turning on medium carbon steel with series number 1045 (AISI 1045) by using carbide insert tool. In this project, the turning process will be performed by using CNC turning machine. No lubricant and cutting fluid will present during the machining as the process is dry cutting operation. The varying parameters are spindle speed and feed rate. The surface roughness of the AISI 1045 carbon steel will be tested by using surface tester while the tool wear of inserts will be evaluated by using optical microscope. The project flow can be simplified as in Figure 1.1.

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Figure 1.1: Project flow

1.5 Concluding Remarks

From this chapter, it can be concluded that there are several problems or major issues that industries are facing in order to obtain good quality of products and to increase the productivity. Surface roughness has a factor that greatly influences on manufacturing cost and this is the main reason manufacturing process employed to create the surface. In CNC turning, there are many parameters cutting conditions that will affect the surface roughness of the workpiece. Hence, a turning process will be conducted on AISI 1045 carbon steel to study the effect of spindle speed and feed rate on the surface roughness of the carbon steel and to identify the optimum parameters.

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CHAPTER 2 LITERATURE REVIEW

2.1 Turning Process

Turning is one of the most important and widely used machining operations, which is carried out on lathe (Kumar et al., 2012). Turning is a form of machining that is a material removal process and can create variety of features and produces smooth finish on cylindrical surfaces (Saini et al., 2014). The removal material process of turning is by a relative motion between a single point of cutting tool and rotating cylindrical workpiece. In a direction that is parallel to the axis of rotation, the cutting tool will fed linearly on the workpiece (Quazi et al., 2013). Figure 2.1 shows the conventional turning machine that can be used for turning process

Figure 2.1: Conventional turning machine (Faizal, 2010)

Turning process requires a lathe which is the turning table, fixture, cutting tool and workpiece. Turning process produces solids of revolution in high tolerance because of the specialized nature of the operation (Hou, 2012). The operation of turning is using only a single point of cutting tool. This has been one of the popular and oldest method of metal cutting.

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operation of an external surface with the rotating workpiece, a single point cutting tool and cutting tool that feeding parallel to the axis of the workpiece. A lathe table is needed to perform turning process in which the tool is stationary and the part is rotated. The fixture on a lathe table are made to secure the workpiece, and able to rotate at high speeds. The schematic diagram of turning process can be shown as in Figure 2.2.

Figure 2.2: Turning process (Hou, 2012)

Typically, part that have many features such as holes, grooves, threads, tapers, variation diameter steps and even contoured surface can be produced by turning process. However, parts that are used in limited quantities, perhaps for prototypes such as shafts and fasteners are parts that are completely fabricated through turning (Jayesh et al., 2014).

In turning, the direction of feeding motion majority is axial with respect to the machine spindle. Facing are named as the generation of surface oriented in the turning is primarily perpendicular to the workpiece axis. Radial feed is dominant in the facing meanwhile tapered and contoured surfaces of workpiece require both modes of the tool feed (Jayesh et al., 2014). Most of the cutting characteristics of turning applications are similar. Once the operation of cutting starts, the tool and workpiece usually in contact until the surface completely generated. The cutting speed and cut dimensions will be constant when cylindrical surface is being turned.

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Nowadays, Computer Numerical Controlled (CNC) machines are widely used in every manufacturing processes. All the functions like tool offset and tool compensation, program editing capability, program storage and various degree of computation can be found with CNC machine (Patel et al., 2012). Besides that, CNC machine has the ability to send and receive data from a various sources and easily realized the remote locations through on board computer. In industries, automated and flexible manufacturing systems are employed to manufacture low cost and high quality product in short time due to the high accuracy and low processing time of CNC machine (Bernandos and Vosniakos, 2002).

CNC turning is a specific form of CNC machining. It rapidly replaced the conventional turning machine such as multi spindle machine and turret machine due to their ease of setting, operation, repeatability and accuracy (Jayesh et al., 2014). CNC turning machine were designed to use modern processes. CNC turning machine can be shown as in Figure 2.3.

2.1.2 Simulation of Turning Process by CNC Machine

In order to simulate the turning process of material removal at a workpiece by CNC machine, a real Computer Aided Design (CAD) has been used. The CAD of material removal simulation gives a close to reality simulation of the real execute Numerical Control program. Before highly complex workpiece being manufactured on CNC machine tool, the manufacturing process need to be checked before proceed to the real machine tool. Most of the Numerical Control (NC) programs are created via Computer Aided Manufacturing (CAM) tools. The software only considers the workpiece and the tools ( Klimant et al., 2014).

However, there were some problems that coming from the CNC machine. When the tool tables wrong or the positions that a specific machine axis cannot be reach, the machining process cannot be simulated (Klimant et al., 2014). This is because the CAM uses the machine and CNC independent cutter location data

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CLDATA file into the machine while the CNC specific the G-code, which is the NC program.

Figure 2.3: CNC turning machine

2.2 Machining Parameters

In turning process, parameters are the main factors to increase the productivity of the machining process. Higher values of cutting parameters offered big opportunities for increasing the productivity but also takes part in the greater risk of deterioration in surface quality and tool life (Yadav et al., 2012). The parameters that involved in the machining of turning were also the same with parameters of different machining process like milling and drilling.

Durabaksa et al. (2015) stated that there were two categories of parameters that can affect the surface quality of machining parts. The first category is machining parameters such as cutting speed, feed rate and depth of cut while the second category is tool characteristic parameters such as coating type and radius. Figure 2.4 shows the parameters that will affect the surface roughness of machined parts.

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Figure 2.4: Parameters that affect surface roughness (Bernandos and Vosniakos, 2002)

Trial and error method was popular among the workers to find the most appropriate cutting condition .The quality of the mating parts plays an important role performance and wear of the mating parts wherever two machined surface came in contact with one and other. A number of factors such as machining variables like cutting speed, depth of cut, feed rate cutting tool wears and other parameters were the main factors of the surface irregularities in machining processes (Harish et al., 2013).

2.2.1 Spindle Speed

Speed (V) is the primary cutting motion that relates to the velocity of the rotating workpiece with respect to the stationary cutting tool. Edge speed of the rotating workpiece is the references of the cutting speed (Syahmi, 2012). The relative movement in the machining operations is produced by the combination of rotatory and translator movement either of the workpiece or of the cutting tool or both. The rate of traverse of the work surface past the cutting edge is called as the „cutting speed‟ (Singh et al., 2014).There will be an optimum cutting speed for some material for a certain set of machining conditions. In finishing process of machining,

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25 preferred (Oguz et al., 2007).

2.2.2 Feed Rate

The situation when the cutting tool (feed) travelling in millimetres per each spindle revolution is the feed rate of turning process (Azza, 2013). Feed rate shows how fast the turning tool moves through the material being cut. It is directly related to the spindle speed and expressed in millimetres per revolution [mm/rev]. Feed rate will decrease with dull tools, a lack of coolant or deep cuts (Syahmi, 2012). Feed rate is the most influential parameter when other parameters are constant. As the tool diameter and spindle speed increase, the surface roughness also increases linearly. This is because and increasing relation exists between the feed rate and the surface roughness.

By statistical method, it is found that feed rate and machining timcontributed significantly to surface roughness. Within the same machining time, a higher feed rate would not degrading surface quality and tool life significantly (Kiswanto et al., 2014). Thus, smooth surface will produce with the lower feed rate. Karabulut (2015) from his research stated that the feed rate has the highest effect on the surface roughness right after the depth of cut and the cutting speed respectively.

2.3 Cutting Tool

In turning process, a single point tool always being used as the cutting tool. Single point tool is a tool that has one cutting edge to remove material from the workpiece. Different machining applications used different cutting tool materials (Azza, 2013). In order to produce good quality parts, cutting tool that was made by harder material than the workpiece material should be used to cut the material.

In any machining process, cutting tools were subjected to high temperature and stresses. Hence, the material of cutting tool must have certain properties such as

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CHAPTER 2

LITERATURE REVIEW

2.1 Turning Process

Figure 2.1: Conventional turning machine (Faizal, 2010)

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Harish et al. (2013) claimed that turning can be defined as the machining operation of an external surface with the rotating workpiece, a single point cutting tool and cutting tool that feeding parallel to the axis of the workpiece. A lathe table is needed to perform turning process in which the tool is stationary and the part is rotated. The fixture on a lathe table are made to secure the workpiece, and able to rotate at high speeds. The schematic diagram of turning process can be shown as in Figure 2.2.

Figure 2.2: Turning process (Hou, 2012)

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2.1.1 CNC Turning

2.1.2 Simulation of Turning Process by CNC Machine

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(CLDATA) format for the simulation. From the CAM, postprocessor converts the CLDATA file into the machine while the CNC specific the G-code, which is the NC program.

Figure 2.3: CNC turning machine

2.2 Machining Parameters

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Figure 2.4: Parameters that affect surface roughness (Bernandos and Vosniakos, 2002)

2.2.1 Spindle Speed

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where low surface roughness is aimed, high cutting speed values always being preferred (Oguz et al., 2007).

2.2.2 Feed Rate

2.3 Cutting Tool

In any machining process, cutting tools were subjected to high temperature and stresses. Hence, the material of cutting tool must have certain properties such as

Study The Surface Roughness Of AISI 1045 Carbon Steel By Using Dry CnC Turning.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA