Effect Of Tool Geometry, Material Hardness And Cutting Parameters On The Cutting Force Turning Process.
I admit that I have read this report and in my opinion this report is sufficient from the
perspective of the scope and quality for awarding purposes Bachelor of Mechanical
Engineering (Them1al Fluid)
Supervisor
Date
｟ＴＬｾ＠
: .......... .. ...
Signature
ame
\\
.... .
: Mr Mohd Nizam Bin Sudin
\'f/\2-{o)
EFFECT OF TOOL GEOMETRY, MATERIAL HARDr ESS AND CUTTf.\JG
PARAMETERS ON THE CUTTING FORCE FOR TUR ING PROCESS
MOHAMAD SAIFUL AZHAR BIN HARUN
This report submitted to Faculty of Mechanical Engineering in fulfillment of the
requirements for the award of the Bachelor of Mechanical Engineering
(Thermal -Fluids)
Facuity of Mechanical Engineering
Kolej Universiti Teknikal Kebangsaan Malaysia
October, 2005
11
DECLARATION
" I hereby, declare that the work in tills report entitled "EFFECT OF TOOL
GEOMETRY, MATERIAL HARDNESS A TD CUTTING PARAMETERS ON
THE CUTTING FORCE FOR TURNING PROCESS" is my own except for
quotations and summaries which have been duly acknowledged "
Signature
Author
:... '}fiJ/ft!tJ.. pljfft!.'-:-..fr)l/fiR:.
Date
:.. (Y.. Ｍｾ ﾷ ｲ＠ .t?i!r?r.. .. ...
if/N
/friRv/1/
Ill
DEDICATION
Dedicated to my belo ved parents and my sisters .... . .
For understanding and moral support
throughout the years ...... .
IV
ACKNOWLEDGMENTS
Firstly, I would like to take this opportunity to express my deepest gratitude
to my project supervisor, Mr. Mohd
Mechanical
Engineering,
Kolej
1zam Bin Sudin from the Faculty of
Universiti
Teknikal
Kebangsaan
Malaysia
(KUTKM), for his support, confidence, and guidance towards completing this
project.
I would like to express greatest thankfulness to Mr. Abd Halim Bin Kling
Head of Department, Germany Malaysian Institute (GMI), who has given advice and
suggestion that contributed into the aspect of metal cutting characterization
throughout the completion of this project.
In particular, I would like to express m y sincere thanks to Mr. Zahir Hassan
for the time spent to give the motivation and morale, all m y friend s and my famil y
for their support in completing this project.
v
ABSTRACT
In this experiment, effect of tool geometries, material hardness, feed rate, and
cutting speed on cutting forces were experimentally investigated. High speed steel
(HSS) tool blank with three type of geometries was prepared and mild steel CF1018
and DF2 steel bars were used as workpiece. Effect of tool geometries material
hardness and cutting parameters on cutting forces statistical anal ysis of variance was
performance. During the experiments two component of tool of tool force and tool
life of cutting tool were measured. This experiment shows that the effect of tool wear
was influenced to increase the cutting force. Different of tool geometries were
showed the variance was performance on cutting force. Where sharp edge show
lower tangential force on CF 1018. The contact between l mm radius (nose radius)
and workpiece had been small impact on cutting force. But honed radius always high
tangential force on CFl 0 18 remarkabl y influence to material hardness also cutting
force. However material hardness is a one of the factors of increased cutting force
and tool life. Therefore, the resulted obtained from the analysis technique indicated
that the longer the cutting tools were in contact with the workpiece, the higher the
rate of wear. The Taylor' s equation derived from the experiment is VT0·15 = 4.78
VI
ABSTRAK
Didalam projek akhir ini, kesan terhadap rekabentuk mata alat dan kekerasan
bahan kerja, kadar masukan dan kelajaun pemotongan didalam proses pemotongan
secara ujikaji diselidik. Dengan menggunakan mara alat yang belum diasah (tool
blank) jenis keluli berkelajuan tinggi (HSS) dengan tiga jenis rekabentuk mata alat
disediakan dan dua jenis bahan kerja yang berlainan kekerasanya iaitu keluli lembut
(mild steel) CFl 018 dan DF2. Kesan rekabentuk mata alat dan kekerasan bahan kerja
terhadap daya pemotongan secara statik dianalysis. Semasa ujikaji dijalankan dua
komponan daya pemotongan, janka hayat mata alat serta kehausan mata alat diukur.
Ujikaji ini menunjukan kesan kahuasan mata alat telah mempengaruhi peningkatan
kepada daya pemotongan. Rekabentuk mata aJat yang berbeza telah menunjukan
kepelbagaian daya
didalam daya pemotongan. Dimana tepi mata alat tajam
menunjukan daya pemotongan menegak adalah rendah terhadap CFl 018. Hubungan
diantara I mm jejari hujung mata alat (nose radius) dan bahan kerja menghasilkan
kesan yang kecil terhadap daya pemotongan. Tetapi hujung mata alat bulat sentiasa
menunjukan nilai yang tinggi didalam daya pemotongan menegak CFl 018 yang
dikatakan mempengaruhi kepada kekersan bahan kerja serta daya pemotongan.
Narnun begitu kekerasan bahan kerja adalah salah satu faktor peningkatan daya
pemotongan dan janka hayat rnata alat. Oleh kerana itu keputusan yang diperolehi
menunjukan semakin panjang ternpoh penggunaan mata alat terhadap bahan kerja,
semakin tinggi kadar kehausan rnata alat. Persamaan Taylor yang diperolehi didalam
ujikaji ini ialah VT0 · 15 = 4.78.
\II
TABLE OF C O NTENT
DECL ARATION ............................................................................................................ ii
DEDICATION ............................................................................................................... iii
ACJ
perspective of the scope and quality for awarding purposes Bachelor of Mechanical
Engineering (Them1al Fluid)
Supervisor
Date
｟ＴＬｾ＠
: .......... .. ...
Signature
ame
\\
.... .
: Mr Mohd Nizam Bin Sudin
\'f/\2-{o)
EFFECT OF TOOL GEOMETRY, MATERIAL HARDr ESS AND CUTTf.\JG
PARAMETERS ON THE CUTTING FORCE FOR TUR ING PROCESS
MOHAMAD SAIFUL AZHAR BIN HARUN
This report submitted to Faculty of Mechanical Engineering in fulfillment of the
requirements for the award of the Bachelor of Mechanical Engineering
(Thermal -Fluids)
Facuity of Mechanical Engineering
Kolej Universiti Teknikal Kebangsaan Malaysia
October, 2005
11
DECLARATION
" I hereby, declare that the work in tills report entitled "EFFECT OF TOOL
GEOMETRY, MATERIAL HARDNESS A TD CUTTING PARAMETERS ON
THE CUTTING FORCE FOR TURNING PROCESS" is my own except for
quotations and summaries which have been duly acknowledged "
Signature
Author
:... '}fiJ/ft!tJ.. pljfft!.'-:-..fr)l/fiR:.
Date
:.. (Y.. Ｍｾ ﾷ ｲ＠ .t?i!r?r.. .. ...
if/N
/friRv/1/
Ill
DEDICATION
Dedicated to my belo ved parents and my sisters .... . .
For understanding and moral support
throughout the years ...... .
IV
ACKNOWLEDGMENTS
Firstly, I would like to take this opportunity to express my deepest gratitude
to my project supervisor, Mr. Mohd
Mechanical
Engineering,
Kolej
1zam Bin Sudin from the Faculty of
Universiti
Teknikal
Kebangsaan
Malaysia
(KUTKM), for his support, confidence, and guidance towards completing this
project.
I would like to express greatest thankfulness to Mr. Abd Halim Bin Kling
Head of Department, Germany Malaysian Institute (GMI), who has given advice and
suggestion that contributed into the aspect of metal cutting characterization
throughout the completion of this project.
In particular, I would like to express m y sincere thanks to Mr. Zahir Hassan
for the time spent to give the motivation and morale, all m y friend s and my famil y
for their support in completing this project.
v
ABSTRACT
In this experiment, effect of tool geometries, material hardness, feed rate, and
cutting speed on cutting forces were experimentally investigated. High speed steel
(HSS) tool blank with three type of geometries was prepared and mild steel CF1018
and DF2 steel bars were used as workpiece. Effect of tool geometries material
hardness and cutting parameters on cutting forces statistical anal ysis of variance was
performance. During the experiments two component of tool of tool force and tool
life of cutting tool were measured. This experiment shows that the effect of tool wear
was influenced to increase the cutting force. Different of tool geometries were
showed the variance was performance on cutting force. Where sharp edge show
lower tangential force on CF 1018. The contact between l mm radius (nose radius)
and workpiece had been small impact on cutting force. But honed radius always high
tangential force on CFl 0 18 remarkabl y influence to material hardness also cutting
force. However material hardness is a one of the factors of increased cutting force
and tool life. Therefore, the resulted obtained from the analysis technique indicated
that the longer the cutting tools were in contact with the workpiece, the higher the
rate of wear. The Taylor' s equation derived from the experiment is VT0·15 = 4.78
VI
ABSTRAK
Didalam projek akhir ini, kesan terhadap rekabentuk mata alat dan kekerasan
bahan kerja, kadar masukan dan kelajaun pemotongan didalam proses pemotongan
secara ujikaji diselidik. Dengan menggunakan mara alat yang belum diasah (tool
blank) jenis keluli berkelajuan tinggi (HSS) dengan tiga jenis rekabentuk mata alat
disediakan dan dua jenis bahan kerja yang berlainan kekerasanya iaitu keluli lembut
(mild steel) CFl 018 dan DF2. Kesan rekabentuk mata alat dan kekerasan bahan kerja
terhadap daya pemotongan secara statik dianalysis. Semasa ujikaji dijalankan dua
komponan daya pemotongan, janka hayat mata alat serta kehausan mata alat diukur.
Ujikaji ini menunjukan kesan kahuasan mata alat telah mempengaruhi peningkatan
kepada daya pemotongan. Rekabentuk mata aJat yang berbeza telah menunjukan
kepelbagaian daya
didalam daya pemotongan. Dimana tepi mata alat tajam
menunjukan daya pemotongan menegak adalah rendah terhadap CFl 018. Hubungan
diantara I mm jejari hujung mata alat (nose radius) dan bahan kerja menghasilkan
kesan yang kecil terhadap daya pemotongan. Tetapi hujung mata alat bulat sentiasa
menunjukan nilai yang tinggi didalam daya pemotongan menegak CFl 018 yang
dikatakan mempengaruhi kepada kekersan bahan kerja serta daya pemotongan.
Narnun begitu kekerasan bahan kerja adalah salah satu faktor peningkatan daya
pemotongan dan janka hayat rnata alat. Oleh kerana itu keputusan yang diperolehi
menunjukan semakin panjang ternpoh penggunaan mata alat terhadap bahan kerja,
semakin tinggi kadar kehausan rnata alat. Persamaan Taylor yang diperolehi didalam
ujikaji ini ialah VT0 · 15 = 4.78.
\II
TABLE OF C O NTENT
DECL ARATION ............................................................................................................ ii
DEDICATION ............................................................................................................... iii
ACJ