DECLARATION. Signature :. Author s Name : Nur Fadila Bte Rasdi.

DECLARATION I hereby, declared this report entitled PSM Title is the results of my own research except as cited in references. Signature :. Author s Name : Nur Fadila Bte Rasdi. Date : 6

APPROVAL This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Process (Process Manufacturing) with Honours. The member of the supervisory committee is as follow: (Signature of Supervisor) (Official Stamp of Supervisor) 7

APPROVAL This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Process (Process Manufacturing) with Honours. The member of the supervisory committee is as follow: (Signature of Principal Supervisor) (Official Stamp of Principal Supervisor) (Signature of Co-Supervisor) (Official Stamp of Co-Supervisor) 8

ABSTRACT In machining of parts, surface quality is one of the most specified customer requirements. Major indication of surface quality on machined parts is surface roughness. Therefore, this study on hard turning process of Ti-6Al-4V aims to investigate the surface roughness mechanism of the hard turning process, determine any significant of parameters that affect the surface roughness mechanism and utilize statistical tool for the analysis of the surface roughness mechanism. This study mainly focused in the investigation on cutting parameter which are feed rate, depth of cut, cutting speed using coated and uncoated cutting tool type. The experimental utilizes the Design of Experiment (DOE) as the approach to develop and analyze the whole study. By utilizing Okuma LCS-15 CNC Lathe machine, 24 numbers of runs was carried out and measured by using Surftest SJ-301. The result shown that for uncoated tools, feed rate was the main parameter that effected to surface roughness while for the uncoated tools the surface roughness most sensitive to cutting speed. 9

ABSTRAK Di dalam pemesinan sesuatu bahagian, kualiti permukaan adalah spesifikasi penting di dalam kehendak pengguna. Indikasi major pada kualiti permukaan adalah kekasaran permukaan. Oleh itu, kajian terhadap pemesinan larik ke atas bahan kerja keluli keras (AISI D2) bertujuan untuk menyiasat mekanisma kekasaran permukaan pada proses melarik, menyatakan sebarang signifikasi parameter yang member kesan pada mekanisma kekasaran permukaan dan menggunakan alatan statistik untuk menganalisa mekanisma kekasaran permukaan. Kajian ini memfokuskan penyiasatan ke atas parameter pemotongan iaitu seperti kadar suapan pemesinan, kadar kedalaman pemotongan, kelajuan pemotongan mengunakan mata alat pemotongan yang bersalut dan tidak bersalut. Kajian experimental ini menggunakan pendekatan Design of Experiment (DOE) untuk membangunkan serta menganalisa keseluruhan kajian. Mesin larik Okuma LCS-15 CNC telah dipilih untuk menjalankan operasi pemesinan ke atas benda kerja dan kadar kekasaran permukaan akan diukur dengan menggunakan Suftest SJ-301. Keputusan menunjukkan bagi mata alat bersalut, kadar suapan pemesinan member kesan pada kekasaran permukaan manakala untuk mata alat tidak bersalut, kekasaran permukaan lebih sensitif terhadap kelajuan pemotongan. 10

DEDICATION For a warmth of love to Abah and Emak, Siblings, friends and my love one. Thank you for the undivided loves and supports. 11

ACKNOWLEDGEMENTS First and foremost, a very thankful to Allah for His mercy, author could finally finish PSM stage 1sucessfully, after experience a lot of obstacles and challenges. Special thanks to Universiti Teknikal Malaysia Melaka for providing an opportunity to every undergraduate student to experience and enhance skills at a specific project and thesis. From this precious moment, a lot of things could be learned by students to prepare themselves to face the global job world once they have graduated. Author cannot fully express to Dr. Bagas Wordono, as the project supervisor for his valuable guides, continuing support, sacrificing his personal time and for truly understanding whenever obstacles happen throughout the entire PSM session. For without his guides and wisdom this PSM report would be ruined. Not forgotten to thank all ADTEC Melaka especially Mr Hisyam Bin Hashim and FKP lecturers who had spent their time to teach, explain and answers all the questions. Last but not list, author also would like to address very enormous appreciation to her family members and to her friends for their enthusiastic support in finance, moral, guidance and all their contributions in order for author to finish this PSM report successfully 12

TABLE OF CONTENT Declaration Aproval Aproval Abstract Abstrak Dedication Acknowledgement Table of Content List of Table List of Figure List of Abbreviations i ii iii iv v ix x xiii 1.0 INTRODUCTION 1 1.1 Background of Study 1 1.2 Problem Statement 3 1.3 Objective 4 1.4 Scope 5 1.5 The Thesis Outline 5 13

2.0 LITERATURE REVIEW 6 2.1 Hard Turning Process 6 2.1.1 CNC Turning Machines 8 2.2 Surface Roughness 10 2.2.1 Surface Roughness Evaluation 11 2.2.2 Roughness Parameters 12 2.2.3 Profile Roughness Parameters 12 2.2.4 Amplitud Parameters 13 2.3.1 Material 14 2.4 Cutting Tools 16 2.4.1 Coated Tools 17 2.4.1.1 Coating Characteristic 17 2.4.2 Common Coating 18 2.4.3 Uncoated Tools 18 2.5 Design of Experiments 19 2.5.1 Key Terminology in Experimental Design 20 2.5.1.1 Set Good Objectives 20 2.5.1.2 Measure Response Quantitatively 21 2.5.1.3 Randomize the Run Order 23 2.5.1.4 Black out Known Sources of variation 23 2.5.1.5 Know Which Effect Will Be Discard 23 2.5.1.6 Do A Sequential Sources of Experiments 23 14

2.5.1.7 Confirm Critical Findings 23 2.5.2 Experimental Design Setup 23 2.5.3 Experimental Method Roadmap (Full Factorial DOE) 25 2.6 Cutting Parameter 25 2.6.1 Feed Rate 26 2.6.2 Cutting Speed 26 2.6.3 Depth of Cut 27 2.7 Previous Journal Review 28 3.0 METHODOLOGY 34 3.1 The DOE Approach 34 3.2 Research Variable 35 3.2.1 Machine Parameters 36 3.2.1.1 Minitab Software 36 3.2.1.2 Analyzing the DOE 38 3.3 Response Variable 39 3.3.1 Surface Roughness Measurement 39 3.4 Experimental Procedure 40 3.5 Experimental Material 40 3.6 Experimental Apparatus 41 3.6.1 CNC Lathe Machine 41 15

3.6.2 Surftest SJ-301 43 3.6.2.1 Procedures 44 3.6.4 XRD Machine 46 3.7 Data Collection 49 3.8 Process Flow Chart 50 4.0 RESULT AND ANALYSIS 51 4.1 Introduction 51 4.2 Surface roughness Analysis 52 4.3 Surface roughness quality 55 4.4 Result and analysis of surface roughness by DOE 57 4.4.1 Coated cutting tools 57 4.4.2 Uncoated cutting tools 66 4.5 Coating Analysis by using XRD Test 73 4.6 Problem Encountered 76 4.6.1 The workpiece (Titanium Alloy) consideration 76 4.6.2 Machine consideration 77 4.6.3 Chipping oriented 78 4.6.4 Chucking mechanism 79 4.6.5 Surface roughness measurement 79 4.6.6 Parameter setting 80 16

5.0 CONCLUSION AND RECOMMENDATION 82 5.1 Conclusion 82 5.2 Recommendation 84 REFERENCES 85 APENDIX 17

LIST OF TABLES 2.1 Nominal chemical composition of Ti-6Al-4V alloy (%) 14 2.2 The mechanical properties of Titanium Alloy 15 2.3 Typical Chemical Analysis 16 2.5 Previous Journal Review 28 3.1 Machining Parameters Used in Experiment and Their Levels 35 3.2 The Orthogonal Arrays for the Experiment 37 3.3 The Okuma LCS-15 CNC Lathe Specification 42 3.4 The Specific Data of Surftest SJ-301 43 3.5 The cutting tools 44 3.6 The process planning for coated cutting tools 45 3.7 The process planning for uncoated cutting tools 48 4.1 Experimental data for surface roughness for coated cutting tool. 52 4.2 Experimental data for surface roughness for uncoated cutting tool 53 4.3 The quality evaluation of Titanium Alloy 55 4.4 The evaluation of surface roughness quality 56 4.5 Main effect plot for surface roughness 62 4.6 Estimated effects and coefficients for surface roughness, Ra 63 4.7 The factors and value to obtain R-squared 64 18

4.8 Analysis of Variance (ANOVA) 64 4.9 R-squared- Relative Significance for coated cutting tools 65 4.10 Main effect plot for surface roughness 70 4.11 Estimated effects and coefficients for surface roughness, Ra 71 4.12 The factors and value to obtain R-squared 72 4.13 Analysis of Variance (ANOVA) 72 4.14 R-squared- Relative Significance for uncoated cutting tools 72 19

LIST OF FIGURES 2.1 The Conventional Turning Machine 7 2.2 The CNC Lathe Machine 8 2.3 The Surface Roughness Parameters 10 2.4 The Depth of Cut 28 3.1 Steps in Minitab Software 36 3.2 Titanium Alloy 40 3.3 The Okuma LCS-15 CNC Lathe 41 3.4 The Surftest SJ-301 42 3.5 The calibration operation. 43 3.6 The X-PERT XRD Machine 45 3.8 The process flow chart 50 4.1 The plotted graph of surface roughness versus run order 53 (Coated cutting tools) 4.2 The plotted graph of surface roughness versus run order 54 (Uncoated cutting tools) 4.3 Residual plot for average surface roughness 57 4.4 The normal plot of standardized effects on the surface roughness 59 4.5 Pareto chart of the standardized effects for the surface roughness 60 4.6 Main effect plotted graph for the surface roughness 61 20

4.7 Interaction plot between the parameters and surface roughness 62 4.8 Residual plot of ANOVA 65 4.9 Residual plot for Average Surface Roughness, Ra. 66 4.10 The normal plot of standardized effects on the surface roughness 67 4.11 Pareto chart of the standardized effects for the surface roughness 69 4.12 Main effect plotted graph for the surface roughness 69 4.13 Interaction plot between the parameters and surface roughness 70 4.14 Residual plot of ANOVA 73 4.15 The average chemical composition in the coated tools. 74 4.16 The intensity versus angle 74 4.17 The cutting operation by using Horizontal Band Saw machine 75 4.18 The facing and drilling operation 76 4.19 The supported workpiece with tail stock 78 4.20 The chip produced during the machining of Titanium Alloy 78 4.21 The surface roughness measurement method. 79 21

LIST OF ABBREVIATIONS % Percentage 0 C Degree Celcius AISI ANOVA CAD CAM CLA CNC Cr CVD DOC DOE F f HB HRC ISO Ipr Mn The American Iron and Steel Institution. Analysis of Variance Computer Aided Drawing Computer Aided Machine Centre Line Average Computer Numerical Control Chromium Chemical Vapor Deposition Depth of Cut Design of Experiment Farenheit Feed rate Brinalls Hardness Number Rockwell Hardness Number International Standard Organization inches per minutes Manganese 22

mm PCBN PVD Ra rev SEM v XRD millimeter PolyCarbon Boron Nitride Physical Vapor Deposition Roughness Average revolution Scanning Electron Microscope. cutting speed X-Ray diffraction 23

CHAPTER 1 INTRODUCTION This study is mainly on the experimental test of the hard turning process on the Titanium Alloy Steel which mainly focuses on the surface quality of the steel. This study on the surface quality will investigate the three main parameters which including the cutting speed, feed rate and the depth of cut using coated and uncoated cutting tools. Thus, this study and investigation will assess the characteristics in high-precision of high - hardened components. 1.1 Background of study. Most machining operations can be divided into those that remove metal from an item, and those that form metal in an item. Often an unfinished workpiece will need to have some parts removed or scraped away in order to create a finished product. For example, a lathe is a machine tool that generates circular sections by rotating a metal workpiece, so that a cutting tool can peel metal off, creating a smooth, round surface. A drill or punch press can be used to remove metal in the shape of a hole. Other tools that may be used for various types of metal removal are milling machines, saws, and grinding tools. Many of these same techniques are used in woodworking. Metal can be formed into a desired shape much more easily than materials such as wood or stone, especially when the metal is heated. A machinist may use a forging machine to hammer or mold a hot metal workpiece into a desired shape. Dies or molds may be used if the metal is soft enough, or under high pressures. A press is used to flatten a piece of metal into a desired shape. Advanced machining operations might use electrical 24

discharge, electro-chemical erosion, or laser cutting to shape metal workpieces. As a commercial venture, machining is generally performed in a machine shop, which consists of one or more workrooms containing major machine tools. Although a machine shop can be a standalone operation, many businesses maintain internal machine shops which support specialized needs of the business. The inferior finish found on the machined surface of a workpiece may be caused by insufficient clamping, cutting conditions or perhaps an incorrectly adjusted machine. It is evident by an undulating or irregular finish, and the appearance of waves on the surface. As quoted from Kaewkuekool, S. et al. (2007), the three principal machining processes are classified as turning, drilling and milling. Other operations falling into miscellaneous categories include shaping, planning, boring, broaching and sawing. Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning. Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling. Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but not uncommonly on lathes or mills. Miscellaneous operations are operations that strictly speaking may not be machining operations in that they may not be chip producing operations but these operations are performed at a typical machine tool. Burnishing is an example of a miscellaneous operation. Burnishing produces no chips but can be performed at a lathe, mill, or drill press. An unfinished workpiece requiring machining will need to have some material cut away to create a finished product. A finished product would be a workpiece that meets the specifications set out for that workpiece by engineering drawings or blueprints. For example, a workpiece may be required to have a specific outside diameter. A lathe is a machine tool that can be used to create that diameter by rotating a metal workpiece, so that a cutting tool can cut metal away, creating a smooth, round surface matching the 25

required diameter and surface finish. A drill can be used to remove metal in the shape of a cylindrical hole. Other tools that may be used for various types of metal removal are milling machines, saws, and grinding tools. Many of these same techniques are used in woodworking. Machining requires attention to many details for a workpiece to meet the specifications set out in the engineering drawings or blueprints. Besides the obvious problems related to correct dimensions, there is the problem of achieving the correct finish or surface smoothness on the workpiece. The inferior finish found on the machined surface of a workpiece may be caused by incorrect clamping, dull tool, or inappropriate presentation of a tool. Frequently, this poor surface finish, known as chatter, is evident by an undulating or irregular finish, and the appearance of waves on the machined surfaces of the workpiece. 1.2 Problem Statement. The challenge of modern machining industries is mainly focused on the achievement of high quality, in terms of workpiece dimensional accuracy, surface finish, high production rate, less wear on the cutting tools, economy of machining in terms of cost saving and increase the performance of the product with reduced environmental impact. Surface roughness plays an important role in many areas and is a factor of great importance in the evaluation of machining accuracy. Many researchers developed many mathematical models to optimize the cutting parameters to get lowest surface roughness by turning process. The variation in the material hardness, alloying elements present in the work piece material and other factors affecting surface finish and tool wear. This experimental study will investigate the influence of surface roughness by cutting parameters such as cutting speed, feed rate, depth of cut and the cutting tool types in order to obtain the best parameters to better finish of surface roughness. Thamizhmanii, S. et al. (2006) Turning is very important machining process in which a single point cutting tool removes unwanted material from the surface of a rotating cylindrical work piece. The cutting tool is fed linearly in a direction parallel to the axis of rotation. Turning is carried 26

on a lathe that provides the power to turn the work piece at a given rotational speed and to feed to the cutting tool at specified rate and depth of cut. Therefore three cutting parameters namely as cutting speed, feed rate, depth of cut utilizing the coated and uncoated type of cutting tools need to be determined in a turning operation. In a typical turning operation, the workpiece is clamped by any one of the workholding devices. Long and slender parts must be supported by a steady rest and follow rest placed on the bed, as otherwise the parts deflect under the cutting forces. These rests usually equipped with three adjustable fingers or rollers that support the workpiece while allowing it to rotate freely. Examples of objects that can be produced on a lathe include candlestick holders, cue sticks, table legs, bowls, baseball bats, musical instruments, crankshafts and camshafts. The turning operations are accomplished using a cutting tool; the high forces and temperature during machining create a harsh environment for the cutting tool. Therefore tool life is important to evaluate cutting performance. The purpose of turning operation is to produce low surface roughness of the parts. Surface roughness is another important factor to evaluate cutting performance. Proper selection of cutting parameters and tool can produce longer tool life and lower surface roughness. Hence, design of experiments (DOE) on cutting parameters was adopted to study the surface roughness. Surface properties such as roughness are critical to the function ability of machine components. Increased understanding of the surface generation mechanisms can be used to optimize machining process and to improve component functionability. 1.3 Objective In particular, the objectives of this study can be described as following: To investigate the surface roughness quality of the hard turning process. 27