v
TABLE OF CONTENT
Abstract i
Abstrak i i
Dedication iii
Acknowledgement i v
Table of Content v
List of Tables i x
List of Figures x
List Abbreviations xii
1. INTRODUCTION 1
1.1 Introduction
1 1.2
Problem statement 3
1.3 Objective
3 1.4
Scope 3
1.5 Importance of study
4 1.6
Result expected 4
2. LITERATURE REVIEW 5
2.1 Turning Process
5 2.2
Parameters 6
2.2.1 Cutting Speed 7
2.2.2 Feed Rate 8
2.2.3 Depth of Cut 8
2.3 Aluminum alloy 6063
9 2.4
Cutting Tool Material 9
2.5 Responses of Turning Process
1 1 2.5.1 Surface Roughness
1 2 2.5.2 Surface Texture
1 3
vi
2.5.3 Vickers Hardness Test 1 4
2.6 Design of Experiment
1 6 2.6.1 Response Surface Methodology
1 6 2.6.1.1 Central Composite Design CCD
1 7 2.6.1.1.1
Factorial Points 1 7
2.6.1.1.2 Star or Axial Points
1 8 2.6.1.1.3
Center Points 1 8
2.7 Summary of Journal
1 9 2.8
Conclusion 2 3
3. RESEARCH METHODOLOGY 2 4
3.1 Flow chart of study
2 5 3.2
Stage 1: Define the objective of the experiment 2 6
3.3 Stage 2: Determine the parameters speed at low level and high level
2 6 3.4
Stage 3: Identify the appropriate responds variable 2 7
3.5 Stage 4: Design of experiment matrix
2 7 3.6
Stage 5: Preparation of the experiment 2 8
3.6.1 OKUMA LCS-15 horizontal machines 2 8
3.6.2 Abrasive cutting machine 2 9
3.6.3 Workpiece preparation 3 0
3.6.3.1 Material properties 3 1
3.6.4 Cutting inserts 3 2
3.6.5 Tool Holder 3 3
3.7 Stage 6: Run the experiment
3 3 3.7.1 Surface Roughness Testing
3 5 3.7.2 Cutting Process Cross Section
3 6 3.7.3 Mounting Process
3 7 3.7.4 Hardness Test
3 9 3.8
Stage 7: Analysis the Results 4 0
3.9 Stage 8: Conclusion
4 0 3.10
Gantt chart for PSM 1 4 1
vii
3.11 Gantt chart for PSM 2
4 2
4. RESULTS AND DISCUSSION 4 3
4.1 Results
4 3 4.2
Analysis of Surface Roughness 4 5
4.2.1 Transformation 4 5
4.2.2 Fit Summary 4 6
4.2.2.1 Sequential Model Sum of Squares [Type I] 4 6
4.2.2.2 Lack of Fit Tests 4 8
4.2.2.3 Model Summary Statistics 4 8
4.2.3 ANOVA 4 9
4.2.3.1 Backward Elimination 5 1
4.2.3.2 Regression Statistics 5 2
4.2.4 Model Diagnostics Plots 5 3
4.2.5 Model Graph 5 5
4.2.5.1 Effect of Feed Rate on Surface Roughness 5 5
4.2.5.2 Effect of Cutting Speed on Surface Roughness 5 7
4.2.5.3 Effect of Depth of Cut on Surface Roughness 6 0
4.2.5.4 Perturbation Graph 6 1
4.2.5.5 Effect of Interaction between Cutting Speed and Feed Rate on Surface Roughness
6 2 4.2.5.6 Effect of Interaction between Depth of Cut and Feed Rate
on Surface Roughness 6 3
4.2.5.7 Cube Plot 6 4
4.3 Optimization
6 5 4.4
Confirmation Run 6 8
4.4.1 Average Deviation Percentage Value 7 0
4.5 Hardness Test
7 1
5. CONCLUSION AND RECOMMENDATIONS 7 3
