TABLE OF CONTENTS
Abstract i
Abstrak ii
Dedication iii
Acknowledgment iv
Table of
Contents v
List of Figures viii
List of Tables x
List of Abbreviations, Symbols, Specialized Nomenclature xi
1.0 INTRODUCTION
1 1.1 Problem
Statement 2
1.2 Objectives 3
1.3 Scope 3
2.0 LITERATURE REVIEW 4
2.1 Computer Numerical Control CNC milling machine 4
2.1.1 CNC
Milling Operation
5 2.1.2
Selection for
Milling Cutter
6 2.2 The Effect of the Surface and Tool in CNC Milling Operation
8 2.2.1 The Influence Factor of the Cutting Condition
8 2.2.1.1
High Speed
Machining 9 2.2.1.2
Feed for
Milling 9
2.2.1.3 Speed
for Milling
10 2.2.1.4
The Cutter
10 2.2.2
Tool Deflection
Test 11
2.2.2.1 Correlation of Deflection Experimental Value with Simple Model 12 2.2.2.2 Stiffness of the Shank and Tool Holder
13 2.2.2.3 Cutting Force Error Determination
14 2.2.2.4 Cutting Force Induced Error Model
14
v
2.2.3 Influence
of Tool
Run-Out 15 2.2.4
Influence of
Ploughing 15
2.3 Tool
Wear 15
2.3.1 Type
of Wear
16 2.3.2
Tool Wear
Effect 17
2.3.2.1 Tool
Run-Out Default
18 2.4
Chip 18
2.5 Surface
Finish 19
2.5.1 Ideal
Surface Finish
20 2.5.2 Impact of Milling Stability onto Machined Surface Roughness
20 2.5.3
Surface on
Unstable Milling
21 2.5.4 The Factor Effect of the Surface Roughness
22 2.6
Overview Design
Experiment DOE
24 2.6.1 The Role and Implication of DOE
24 2.6.2
Orthogonal Array
OA 25
3.0 METHODOLOGY
27 3.1
Introduction 27
3.2 Study Tool Length Effect in Machining Operation 31
3.3 Design
of Experiment
31 3.3.1 Tool Length 33
3.3.2 Feed Rate 34 3.3.3
Speed 34
3.4 Prepare
the Sample
34 3.4.1
Mild Steel
35 3.4.2
Tool Steel
35 3.5
Machine Selection
35 3.5.1
G- Code
37 3.5.1.1
Machining Process
38 3.5.2
Cutting Tool
40 3.6
Data Collection 40
3.6.1 Portable Surface Roughness Tester 41
vi
3.6.1.1 Surface
Roughness Measurement
41 3.6.2
The Metallurgy
Microscope 42
3.6.3 Dial
Caliper 43 3.7 Analyze the Data 44
4.0 RESULTSANALYISIS
45 4.1
Introduction 45
4.2 Surface
Roughness Result
45 4.2.1 Analysis for Significant Parameter
47 4.2.2 Surface Roughness Analysis for Mild Steel Material
47 4.2.3 Surface Roughness Analysis for Tool Steel Material
51 4.3
Chip Thickness
Result 56 4.3.1 Chip Thickness Analysis for Mild Steel
57 4.3.2 Chip Thickness Analysis for Tool Steel
58 4.4
Observation of
Tool Wear
60
5.0 DISCUSSIONS
