THE INFLUENCE OF MACHINING PARAMETERS ON
TOOL WEAR AND SURFACE FINISH
NOR HARIYANI BINTI ABD WAHAB
B050810303
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
THE INFLUENCE OF MACHINING PARAMETERS ON TOOL
WEAR AND SURFACE FINISH
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process)
by
NOR HARIYANI BINTI ABD WAHAB B050810303
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: The Influence of Machining Parameters on Tool Wear and Surface Finish
SESI PENGAJIAN: 2010/11 Semester 2
Saya NOR HARIYANI BINTI ABD WAHAB
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
DECLARATION
I hereby declare that this report entitled “THE INFLUENCE OF MACHINING PARAMETERS ON TOOL WEAR AND SURFACE FINISH” is the result of my own research except as cited in the references.
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 Engineering (Engineering Process). The member of the supervisory committee is as follow:
ABSTRAK
ABSTRACT
ACKNOWLEDGEMENT
DEDICATION
TABLE OF CONTENT
1.3 Experimental Design 1.3.1 Objectives
1.4.1 Chapter 1: Introduction 1.4.2 Chapter 2: Literature Review 1.4.3 Chapter 3: Methodology
1.4.4 Chapter 4: Result and Discussion
1.4.5 Chapter 5: Conclusion and Recommendations
5
2. LITERATURE REVIEW 7
2.1 Turning Operation 2.2 Cutting Operation
2.2.1 Orthogonal cutting process
2.3 Wear
2.3.1 Wear characterization 2.3.2 Wear mechanisms of tools 2.4 Tool wear mechanism 2.5 Tool wear measurement 2.5.1 Tool life
2.5.2 Tool failure modes 2.5.3 Tool Life Test 2.6 Cutting Tool Materials
14
2.8 Surface Roughness Measurement 34
2.8.1 Surface Roughness in Turning 2.9 Observations of chip formation
2.10 Turning Process Parameter That Effect the Surface Roughness and Tool Wear
2.11 Single point tools 2.12 Design of Experiment 2.12.1 Full Factorial Experiment
3.8.1 Scanning Electron Microscopy Analysis (SEM) 58
3.9 Method to Analyze Surface Roughness 60
3.10 Data Analysis 61
4. RESULT AND DISCUSSION 62
4.1 Introduction 62
4.2 Tool Wear Result 62
4.3 Surface Roughness Result 69
4.4 Design of Experiments
4.4.1 ANOVA Balanced (Tool wear versus Depth of cut, Feed
Rate, Cutting speed)
4.4.2 Pareto Chart of the Standardized Effects 4.4.3 Main Effects Plot for Tool Wear
4.4.4 Interaction Plot for Tool Wear
4.4.5 ANOVA Balanced (Surface roughness versus Depth of cut, Feed rate, Cutting speed)
4.4.6 Pareto Chart of the Standardized Effects 4.4.7 Main Effects Plot for Surface Roughness 4.4.8 Interaction Effects Plot for Surface roughness 4.5 Development of Mathematical Modelling
70
5. CONCLUSION AND RECOMMENDATION 81
LIST OF TABLES
Table 2.1 Types of cutting tool wear 16
Table 2.2 Flank wear of variety cutting tool 30
Table 2.3 The General Properties of Cutting Tool Materials 34 Table 2.4 Factors influencing formation of chips 40 Table 2.5 Parameter that Effect Surface Roughness and Tool
Wear
41
Table 2.6 2³ Factorial design ‘Standard Order’. 45
Table 3.1 Chemical Composition Specification. 49
Table 3.2 Sumitomo SPGN120308S cutting tool dimensions 50 Table 3.3 General Properties of Tungsten Carbide 50
Table 3.4 Function of Lathe Machine 54
Table 3.5 The Cutting Parameter Range in accordance with ISO 229.
55
Table 3.6 DOE Matrix 57
Table 3.7 Factors and Levels selected for the Experiments 58
Table 4.1 Flank Wear Result. 63
Table 4.2 Result of Surface Roughness 69
Table 4.3 Result for surface roughness and tool wear to analysis
70
LIST OF FIGURES
Figure 1.1 Single lathe turning machine 2
Figure 1.2 Experimental design of lathe process 3
Figure 2.1 Types of cutting such as (a)orthogonal and(b) simulated slip-line fields in orthogonal cutting
10
Figure 2.4 Heat generation 12
Figure 2.5 Orthogonal machining 12
Figure 2.6 Configuration for orthogonal cutting 13
Figure 2.7 A turning tool insert wear pattern 19
Figure 2.8 Schematic of tool wear distribution 20
Figure 2.9 Typical wear patterns of turning tool using carbide insert
20
Figure 2.10 Abrasive wear 21
Figure 2.11 Adhesive Wear 22
Figure 2.12 Wear of large scale plastic deformation 23
Figure 2.13 Wear of fatigue and fracture 24
Figure 2.14 Diffusion wear of the cutting tool 25
Figure 2.15 Conventional tool wear measurement 30
Figure 2.16 Common properties of cutting tool materials 32 Figure 2.17 Cutting speed and feed capability of various
cutting tool materials
33
Figure 2.20 Effect of feed rate and edge preparation on surface roughness (Ra). Workpiece hardness 47 HRC AISI 51200 steel
37
Figure 2.21 Discontinuous Chip 39
Figure 2.22 Continuous Chip 39
Figure 2.23 Continuous Chip with Built-up Edge 40
Figure 2.24 Turning tool geometry showing all angles 42 Figure 2.25 Tool designations for single point cutting tool 43 Figure 2.26 A 2³ two-level, full factorial design; factors X1,
X2, X3.
45
Figure 3.1 Flow chart process 47
Figure 3.2 Process Flow Chart. 48
Figure 3.3 Tungsten carbide cutting tool insert commercially made by Sumitomo
49
Figure 3.4 Single Turning Lathe machine 51
Figure 3.5 A typical lathe machine 51
Figure 3.6 Single Turning Lathe machine the process 52
Figure 3.7 Scanning Electron Microscopy (SEM) 60
Figure 3.8 Portable Surface Roughness Tester: Model Surftest SJ – 301
61
Figure 4.1 ANOVA Balanced (Tool wear versus Depth of cut, Feed rate, Cutting speed)
71
Figure 4.2 Pareto Chart of the Standardized Effects 72
Figure 4.3 Main Effects Plot for Tool Wear 73
Figure 4.4 Interaction Plot for Tool Wear 74
Figure 4.5 ANOVA Balanced (Surface roughness versus Depth of cut, Feed rate, Cutting speed)
75
LIST OF ABBREVIATIONS
AA CLA
- -
Arithmetic Average Centreline Average
ANOVA - Analysis of Variance
ap - Depth of Cut
BUE - Built Up Edge
DOE - Design of Experiment
f - Feed Rate
ISO - International Standard Organisation
Ra - Surface Roughness
TiC - Titanium Caride
VBB - Flank Wear Land
vs - Cutting Speed
CHAPTER 1
operation uses the simple single point cutting tool. In turning, the speed and motion of the cutting tool are commonly influence by several parameters such as cutting speed, depth of cut, cutting fluids and characteristics of the machine tool. These parameters are determined for a particular operation based on the workpiece material, tool material, tool size and more (Kalpakjian, 2006).The material of the tool is chosen based on a number of factors, including the material of the workpiece, cost, and tool life. Tool life is an important characteristic to be considered when selecting a tool, as it greatly influences manufacturing costs. The cutting tools can be made of various materials, which will determine the tool's properties. These properties include the tool's hardness, toughness, and resistance to wear (Dimla et.al., 1998).
Wear is loss of material which usually progress continuously. Progressive wear of a
tool takes place mainly in two distinct ways which is wear on the rake face by the
formation of crater or built up edge resulting from the action of chip flowing along
the face and wear on the flank face including often regions adjacent to the major and
minor cutting edges and tool nose, where as characteristic land is formed from
rubbing action of newly generated workpiece surface (Grzesik, 2008).
The damages of cutting tool are influenced by certain factor such as stress and
temperature at tool surfaces which in turn depend on cutting mode such as turning,
drilling or milling, cutting condition and also the presence of cutting fluid in the
process. In machining, the tool damaged and its rate are very sensitive to changes in
cutting operation and cutting conditions. This is very important in order to minimize
machining cost. It is not only to find the most suitable tool and work material for the
machining operation, but also to predict the tool life. Today, modern cutting tools
have progress enormously increasing their cutting speeds and tool life, due to the
materials being used and a better understanding of the cutting parameters. Figure 1.1
1.2 Problem Statement
Tool wear and surface finish were studied in this project. In general, the development of new cutting tools is driven by three factors; the constant demand for increased productivity, the advent of difficult to machine materials and growing environmental, health and safety issues. This study focuses on the cutting tool wear, measured using scanning electron microscope and also its effect on workpiece roughness measured using portable profilometer. This project studied the influence of machining parameters on tool wear and workpiece surface finish using full factorial Design of Experiment.
This study is aimed to find out the answer for the following questions:
i. Which machining parameters (depth of cut, cutting speed and feed rate) significantly influence cutting tool wear and workpiece surface roughness? ii. How does the change in machining parameters‟ values effect the cutting tool
wear and surface roughness?
iii. Is there interaction between the process parameters that affect tool wear and workpiece surface roughness?
Figure 1.2: Experimental Design of Lathe Process.
Input Parameter Output Parameter
Figure 1.2 shows that the experimental design approach of to achieve the objectives of this research. The input parameters in the experiment are cutting speed, feed rate and depth of cut. The output responses of the experiment are the tool wear and surface roughness. Full factorial with two levels was adopted as experimental approach.
1.3.1 Objectives
The objectives of this study are:
(a) To identify machining parameters (depth of cut, cutting speed and feed rate) that significantly influence tool wear and workpiece surface roughness.
(b) To ascertain the effect of the change in machining parameter values on the tool wear and workpiece surface roughness.
(c) To determine if there are interactions between the process parameters that significantly affect tool wear and workpiece surface roughness.
1.3.2 Scopes of Study
1.4 Structure of the report
The summary of each chapter was described in the structure of report. The structure of the report includes Chapter 1 until Chapter 5 of the report.
1.4.1 Chapter 1: Introduction
Include the background of the project, problem statement, experimental design, objectives, scope and project management of the whole project.
1.4.2 Chapter 2: Literature Review
Literature review on wear characterization, surface roughness, the explanation single point turning lathe machine is based on its history, classification, application and production processes.
1.4.3 Chapter 3: Methodology
The methodology of the project contains a brief explanation about the preparation of the experiments including the equipment used measurement on tool wear and surface roughness, experimental approach using full factorial Design of Experiment method, and the data analysis using Minitab software.
1.4.4 Chapter 4: Result and Discussion
1.4.5 Chapter 5: Conclusion and Recommendations
CHAPTER 2
LITERATURE REVIEW
2.1 Turning Operation
Machining is one of the most versatile processes in the manufacturing industry for processing, shaping or cutting various types of work piece materials. Machining is defined as a material removal process that is applied to a workpiece in order to get the required shape. Variety shapes can be produced by machining (Kalpakjian et.al., 2006). Currently there is a lot of emphasize given to develop the machining capabilities in order to achieve near net shapes and also to reduce cost of the machining method, tools and equipments. In the metal cutting process unwanted material is removed from a workpiece in the form of chips for producing finished parts of required dimensions and accuracy. Metal cutting is a highly non-linear and coupled thermo mechanical process, where the mechanical work is converted into heat through the plastic deformation involved during chip formation and also due to frictional work between the tool, chip and workpiece (Chandrakanth, 2000).
(a) Orthogonal cutting (b) Oblique cutting
Figure 2.1:Types of cutting (a) orthogonal and (b) oblique cutting (Ghosh et.al., 1986).
