3.7.1.7 Analyze the result
The result will be analyze based on the data obtain. The chapter 4 is about the data collection will be discussing the relationship between the parameter will response the
result.
3.8 DOE Matrix
The table 3.6 shows the numbers of cutting parameter that need to be tested. There are three parameters which are cutting speed, feed rate, and radial depth of cut. The surface
roughness will be measure after machining process is done.
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Table 3.6: DOE matrix
Standard Run
Block Cutting speed
,Vc mmin Feed rate,fz
mmtooth Width of
cut, ae mm
Surface roughness
12 1
Block 1 125
0.2 8
13 2
Block 1 125
0.15 5
5 3
Block 1 100
0.15 2
14 4
Block 1 125
0.15 5
7 5
Block 1 100
0.15 8
2 6
Block 1 150
0.1 5
9 7
Block 1 125
0.1 2
11 8
Block 1 125
0.1 8
1 9
Block 1 100
0.1 5
10 10
Block 1 125
0.2 2
4 11
Block 1 150
0.2 5
15 12
Block 1 125
0.15 5
8 13
Block 1 150
0.15 8
6 14
Block 1 150
0.15 2
17 15
Block 1 125
0.15 5
16 16
Block 1 125
0.15 5
3 17
Block 1 100
0.2 5
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3.9 MACHINING PROCESS
3.9.1 SAMPLE PREPARATION
The work piece material of D2 tool steel taken from the laboratory and then the size is measured by using measuring tape. The measurement of the work piece is 200mm x
210mm x 100mm. Before start the machining process, the surface of this material need to be milling facing. As a facing process the work piece is requires 90 degrees flat
milling table, then the work piece is square milled by using face milled. The reason for accomplishment facing process is to remove the contaminant and corrosive at the
surface of the work piece. At the first stages facing process however is not affect the end result of surface roughness parameter.
3.9.2 MILLING MACHINE PREPARATION
The end mill have two insert made from TiAlN with the diameter 20mm is place in a tool holder. Based on the NC program the tool holder is set as tool 1 T1 placed into
a proper tool slot. Before the machining is start, the air gun is used to clean off a chip or dirt that lingers on the milling cutter and the milling table. The machine that will
used is shown in figure 3.2
Figure 3.2: HAAS 3-axis CNC milling machine
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3.10 MEASURING SURFACE ROUGHNESS
Surface roughness testers are the method to investigate the surface roughness on the work piece after the machining process is done. This method is the best in which the
industry looking to improve good surface finish of product that produced. The value of Surface roughness parameter is measured with using a portable Mitutoyo SJ-301
see figure 3.3. The detectors can be retracted back into the drive unit and it has high accuracy widely can be measuring until 300μm. The measurement of average
roughness Ra is the area between the roughness profiles obtain from machining and
it means a line or a significant elevation in the absolute value of the roughness profile over the length. Measurement value is displayed on a digital touch panel, and the
output result can be print out from the built-in printer. Surface roughness is measured from the vertical displacement of stylus with driving direction on the detector flat
surface. The result is displayed digitally or graphics on the touch panel.
Figure 3.3: MITUTOYO SJ-301
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CHAPTER 4
RESULT AND DISCUSSION
4.1 INTRODUCTION
This chapter is explain the result obtained from the experiment, the machining process perform using PVD end mill cutting tool with D2 tool steel of work piece material.
The result presented and discussed is followed the statistics and scientific method. The problem and the findings discussed were the ability of machining process using
D2 tool steel to build a mathematical model using statistical analysis for the cutting parameters and the quality of the surface roughness. Then was followed by
determining the optimum machining process to meet all the response simultaneously and proved by model validation. The performance of cutting parameter can be assessed
by examining the causes of surface roughness and failure mechanism of cutting tool that occur. The Surface integrity of the machined work piece is examined in detail.
The study consists of contributions; equation to predict the cutting parameters resulting in the phenomenon of inconsistency in the effects of surface roughness grinding end
mill cutting tool. In this experiment, the objective was to find a combination of cutting parameter
namely cutting speed, feed rate and width of cut that will give the low of surface roughness and at the same time, others factors taken into account where the economic
productivity of machining are analyzed in terms of the costs involved in the machining and then compared with other researchers.
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4.2 THE SURFACE ROUGHNESS
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