ix
LIST OF FIGURE
2.1 Elements of Machining Process
8 2.2
Example of Milling Process 9
2.3 DMF 250 Linear Deckel Maho
11 2.4
Geometry of End Mill 13
2.5 Hob Cutter
14 2.6
Vertical Hobbing Machine 14
2.7 Fly Cutter
15
2.8 Brass Wheels Being Cut by a Fly Cutter
15 2.9
Geometry of a Ball Nose Milling Cutter and its Static Solid Model 16
2.10 Enlarged Image of a Ball Nose Cutter Tool Tip Using SEM
16 2.11
Schematic Diagram CVD Coating Method 24
2.12 Schematic Diagram of PVD Process
26 2.13
Metal Alloy Classification 27
2.14 White Cast Iron
28 2.15
Chilled Cast Iron 29
2.16 Gray CI, Fe, 3.2 C, and 2.5 Si wt,
30 2.17
Microstructure for Ferrictic Ductile Cast Iron 31
2.18 Surface Characteristic
34 2.19
Surface Symbol 35
2.20 Example of surface defects
37 2.21
Surface Defects 38
2.22 Microcracks
39 2.23
Plastic Deformation 39
2.24 Slip
40 2.25
Twinning 41
2.26 plastic deformation beneath the machined surface
43
x
3.1 Research Methodlogy
46 3.2
The Main Grey Cast Iron Grades Worldwide 47
3.3 Ball End Mill 32mm Hitachi ABPF-32 MT4
45 3.4
Insert for Ball End Mill 32mm 50
3.5 DMF 250 Linear Deckel Maho
51 3.6
Range cutting speed mmin for machining a different workpiece material 52 3.7
Automatic Moulding Machine 53
3.8 Automatic GrindingPolishing Equipment
54 3.9
Scanning Electron Microscope 55
3.10 Rockwell Hardness Tester Mitutoyo Wizhard HR-500
56
4.1 Microstructure of the grey cast iron
58 4.2
Microstructure bent when machining at cutting speed of 6000 rpm, 60
feed rate of 5 mmin, and depth of cut of 0.1 mm. 4.3
Microstructure bent when machining at cutting speed of 7000 rpm, 60
feed rate of 5 mmin, and depth of cut of 0.1 mm. 4.4
Microstructural alteration in FC300 cast iron 61
4.5 White layer formation under condition of cutting parameter 8000 rpm,
63 feed rate of 7 mmin and depth of cut of 0.1 mm
4.6 Hardness variations after machining FC 300 cast iron with dry machining 65
under the conditions where the cutting speed is 6000 rpm, depth of cut of 0.1 mmmin
4.7 Hardness variations after machining FC 300 cast iron with dry machining 66
under the conditions where the cutting speed is 7000 rpm, depth of cut of 0.1 mmmin.
4.8 Hardness variations after machining FC 300 cast iron with dry machining 66
under the conditions where the cutting speed is 8000 rpm, depth of cut of 0.1 mmmin.
xi
4.9 Hardness variations after machining FC 300 cast iron with dry machining 67
under the conditions where the cutting speed is 9000 rpm, depth of cut of 0.1 mmmin.
xii
LIST OF ABBREVIATIONS
MMSB -
Miyazu Malaysia Sdn Bhd UTeM
- Universiti Teknikal Malaysia Melaka
ASTM -
American Society for Testing and Material JIS
- Japanese Industrial Standard
SEM -
Scanning Electron Microscope Cbn
- Cubic Boron Nitride
CNC -
Computer Numerical Method HSM
- High Speed Machine
HSS -
High Speed Spindle MRR
- Material Removal Rate
Ra -
Arithmetic Average Rpm
- Revolution per Minute
HIP -
Hot Isostatic Pressing CVD
- Chemical Vapor Deposition
PVD -
Physical Vapor Deposition WC
- Tungsten Carbide
TiN -
Titanium Nitride TiC
- Titanium Carbide
CI -
Cast Iron
1
CHAPTER 1
INTRODUCTION
1.1 Introduction
