Investigation Of Influence Of Slender Cutting Tool And Cutting Parameters On Product Quality

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

INVESTIGATION OF INFLUENCE OF SLENDER CUTTING

TOOL AND CUTTING PARAMETERS ON PRODUCT

QUALITY.

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Process) (Hons.)

by

NORAIDA BINTI ABDUL AZIZ B050910212

890115-03-5578

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

TAJUK: Investigation of Influence of Slender Cutting tool and cutting Parameters on Product product Quality.

SESI PENGAJIAN: 2012/13 Semester 2

Saya NORAIDA BINTI ABDUL AZIZ

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 sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS)

Alamat Tetap:

NO 3 JPN BLOK A,

KEPAS LATI 17000 PASIR MAS,

KELANTAN DARUL NAIM

. Tarikh: _________________________ Disahkan oleh: (TANDATANGAN PENYELIA) Cop Rasmi: Tarikh: _______________________

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 (Process Engineering) (Hons.). The member of the supervisory is as follow:

………

DECLARATION

I hereby, declared this report entitled “Investigation of Influence of Slender Cutting Tool and Cutting Parameters on product quality” is the results of my own research

except as cited in references.

Signature :

Author’s Name : Noraida Binti Abdul Aziz

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ABSTRACT

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ABSTRAK

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ACKNOWLEDGEMENT

First of all, We would like to express my gratitude to all those who gave me the possibility to complete this project. I am deeply indebted whose help, stimulating suggestions and encouragement helped us in all the time of this project among this report in progress until done.

. Big thanks to my academic supervisor. He has been helping me out in the academic field including finishing this technical report. And not to forget to School of Process Engineering staff and lecturers and other UTeM staffs and lecturer and who had been involving directly or indirectly though out this process. Without their help and support, it would have been tougher for me to go through my PSM 1 as part of Final year project furthermore to finish my report.

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DEDICATION

We would like to , I would like to thank to all those who gave me the possibility to complete this project. I am deeply indebted to my lecturer, Encik Ab Rahman Mahmood whose help, stimulating suggestions and encouragement helped us in all the time of this project. We have further more to thanks to technician that willing to provide help to us in running among the experiment for drilling process.

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TABLE OF CONTENT

Abstract i

Abstrak ii

Acknowledgement iii

Dedication iv

Table of content v

List of figure ix

List of table xi

List Abbreviations, Symbols and Nomenclatures xii

CHAPTER 1.0 : INTRODUCTION 1

1.1 Background 6

1.2 Objective 6

1.3 Scope of Project 7

1.4 Problem Statement 8

1.5 Outline of report 8

CHAPTER 2.0 : LITERATUTURE REVIEW

2.1 Drilling 10

2.2 CNC Machining centre 12

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2.3.1 Solid Carbide 16

2.3.2 Special Solid Carbide Tools 17

2.3.3 Carbides (uncoated tool) 18

2.3.4 Coated carbide (coated tool) 18

2.3.5 High Speed Steel Drill (HSS) 19

2.4 Tool holder For Drills 21

2.5 Causes of Drill Failure 22

2.6 Aluminum alloy 23

2.6.1 Machining of aluminum alloys 23

2.6.2 Alloy elements 24

2.6.3 Important when machining aluminum alloys 24

2.6.4 Practical use 24

2.7 Intelligent parameter selection 25

2.7.1 Cutting speed 25

2.7.2 Feed rate 27

2.7.3 Tool Length 28

2.7.4 Hole depth 29

2.7.5 Machines Vibration 30

2.7.6 Hole diameter accuracy 32

2.8 Mathematical model 34

2.8.1 Accelerometer 34

2.8.2 Linear Regression 35

2.8.3 Vibration 36

CHAPTER 3.0 : METHODOLOGY 38

3.1 Introduction 38

3.2 Procedure of Project 41

3.3 Procedures of experiment 41

3.3.1 Objective 41

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3.3.2.1 Cutting speed 43

3.3.2.2 Feed Rate 44

3.3.2.3 Tool Length 45

3.3.2.4 Work piece and insert 46

3.3.2.5 Vibrations 46

3.3.2.6 Final dimension of sample of work piece 47

3.4 Table matrix design 47

3.5 Data Acquisition 48

3.5.1 Accelerometer 48

3.5.2 CNC machining centre 50

3.5.3 Experimental setup 51

. 3.5.4 Sample measurement 53

CHAPTER 4.0 : RESULT AND DISCUSION

4.1 Result 54

4.1.1 Sampling Data Structure 55

4.1.2 Drilling Operation 56

4.1.3 Experimental Results 59

4.2 Discussion 61

4.2.1 Hole diameter Accuracy measurement 61

4.2.2 Vibrations collections 62

4.2.3 Main effect plot 64

4.2.4 Multiple regression modeling 65

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4.2.9 Regression analysis for y-axis 70 4.2.10 Best subsets for constructing best model for x-axis 71 4.2.11 Constructing Best Model for Y-axis 72

4.2.12 Residual plots For x-axis 73

4.2.13 Normal Probability Plot for Hole Diameter 74

4.2.14 Histogram 74

4.2.15 Residual plot versus order 75

4.2.16 Normal Probability Plot for Hole Diameter 76 4.2.17 Residual plots versus fitted values 76

4.2.18 Histogram 76

4.2.19 Residual plot versus order 77

4.3 Model Validation 77

4.3.1 Unpaired Test for x-axis 77

4.3.2 Null Hypothesis x-axis 79

4.3.3 Unpaired Test for y-axis 80

4.3.4 Null hypothesis y-axis 82

CHAPTER 5.0 : CONCLUSION AND RECOMENDATION

5.0 Conclusion 83

5.1 Recommendation 85

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LIST OF FIGURES

1.1 Flow chart represents the scope of work 7

2.1 Experimental Set up of vertical CNC and Line diagram

of experimental set up Drilling machine 12

2.2 CNC PCB Drilling Machine Design. 13

2.3 Hot hardness of different tool materials 15 2.4 Example of Solid carbide cutting tool for aluminum 16

2.5 Special Solid Carbide Tools 17

2.6 Cutting tool material - hardness in relation to toughness 20

2.7 Example of tool holder 21

2.8 Cutting speed, penetration rate, spindle speed and feed per revolution

and main hole-machining factors 26

2.9 Relationship of feed rate to speed 27

2.10 The range of applicable cutting speeds and feeds for

a variety of tool materials 27

2.11 Feed Rate for Drilling Aluminum 28

2.12 Example of tool length 29

2.13 Equipment set-up on a vertical machining center 32

2.14 Hole diameter 33

2.15 Hole accuracy and positioning 33

2.16 Mathematical formula 34

2.17 Accelerometer equipment 35

2.18 Vibration form in time domain and frequency domain 37

3.1 Project planning flowchart 39

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3.3 Schematic Diagram of the experiment setup 43

3.4 Cutting Speed for each sample 44

3.5 Feed Rate for each sample plate 45

3.6 Tool Length for each sample plate 45

3.7 Aluminum Alloy and Drilling Insert for this experiment 46

3.8 Accelerometer will be use 48

3.9 Main user interface overview 48

3.10 Data acquisition control panel 49

3.11 CNC machining centre 50

3.12 Set up for measuring Hole diameter 51

3.13 Schematic diagram of the experiment setup 52

3.14 Coordinate Measuring Machine (CMM) 53

3.15 Hole Diameter 53

4.1 CNC machining mechine 56

4.2 Aluminum alloy after machining process 57

4.3 illustrated hole making 58

4.4 CMM machine 61

4.5 Vibration waveform signals of x, y and z axis 63

4.6 Insert data in Minitab 65

4.7 Regression analysis 66

4.8 Best subset 66

4.9 Regression analysis based on best subset 67

4.10 Insert y-axis data in Minitab 69

4.11 Regression analysis 70

4.12 Best subset 70

4.13 Regression analysis based on best subset 71

4.14 Residual plot for Hole Diameter 73

4.15 Residual plots for hole diameter 75

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LIST OF TABLE

2.1 Advantage and disadvantage CNC 14

2.2 Causes of Drill Failure 22

3.1 The desired parameter value 47

4.1 Experiment data 55

4.2 Experimental Result and the Response, Hole Diameter x-axis 59 4.3 Experimental Result and the Response, Hole Diameter Y-axis 60

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LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURES

ECM - Electrochemical machining CHM - Chemical machining DOE - Design of Experiment ANOVA - Analysis of variance

OHNS - Otolaryngology Head and Neck Surgery

MINITAB - Statistical and Process Management Software for Six Sigma and Quality Improvement

PSM - Projek Sarjana Muda HSS - High-speed steel TiN - Titanium nitride

CNC - Computerized Numerical Control PCB - CNC Printed Circuit Board PC - Personal Computer

CAD - Computer-aided design TSP - Thrift Savings Plan SGS - Intertek Agri Services WC - Tungsten carbide

CVD - Chemical vapor deposition PVD - Physical vapor deposition TiC - Titanium carbide

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ASTM - International develops international standards for materials SAE - Society of Automotive Engineers

Si - Silicon

Mg - Magnesium

Mn - Manganese

Cu - Copper

Zn - zinc

EDM - Electric discharge machining

ANFIS - Adoptive neuro-fuzzy inference system TiALN - Titanium aluminum nitride

PFX - Phoenix Companies ADX - Average Directional Index

MM - Millimeter

MRR - Material removal rate

VibDAQ - Vibration monitoring software application FFT - Fast Fourier Transform

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CHAPTER 1

INTRODUCTION

Drilling processes are widely used in the aerospace, aircraft and automotive industries (Mustafa Kurt et.al, 2009). Although that non-traditional machining methods have improved in the manufacturing industries in response to new and unusual machining requirement that could not be satisfied by conventional methods. Non-traditional machining including ultrasonic machining, abrasive water jet cutting, electrochemical machining (ECM), and chemical machining (CHM) are some of the example but conventional drilling still remains one of the most common machining processes.

Furthermore, The largest amount of money spent on any one class of cutting tools is spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes are extremely important for the manufacturing industry (S.A. Jalaliet.al 1991). Amongst traditional machining processes, drilling is one of the most important metal cutting operations, comprising 33% of all metal cutting operations (Chen W C et.al, 1999). Although modern metal cutting methods have tremendously improved in the manufacturing industry, conventional drilling process still remains one of the most common processes.

Page | 5 Drilling operation usually is evaluated based on the performance characteristics strongly correlated with the cutting parameters such as cutting speed, feed, tool length, and vibration. Three parameters speed, feed and tool length are selected as controllable parameters and non controllable like hole diameter accuracy are considered as the required quality characteristic responses. Several mathematical models based on statistical regression have been constructed to establish the relationship between the cutting performance and cutting parameters. Han-Ming Chow ct.al, 2008 has explored how different parameters such as drill shape, friction angle, friction contact area ratio, feed rate, and drilling speed would affect the response parameter for austenite stainless steel (AISI 304) using taguchi method.

A statistical technique, fractional factorial experiments and analysis of variance (ANOVA), has been employed to investigate the influence of cutting parameters on the hole diameter accuracy quality that means Taguchi design is proved to be an efficient tool to produce high quality products at very less cost. The objective of taguchi robust design is to determine the optimal parameter settings and making the process performance insensitive to various sources of variations. The approach can economically satisfy the needs of the problem solving and design optimization. Taguchi technique allows the process optimization with minimum number of experiments without need for process model development.

Thus, by this method, it is possible to reduce the time and cost for experimental investigations and thus enhance the performance characteristics. Factors affecting surface roughness were determined and thus conclusions were drawn about optimizing all the cutting parameters for better hole diameter accuracy. Many factors affect hole diameter quality, which can be divide into controllable and non-controllable (Shashidhar Madiwal, 2006).

Controllable Factors: Speed Feed Rate Hole Depth Drill Geometry

Material of Cutting Tool Non-Controllable Factors: Machine Accuracy

Page | 6 Taking the above factors into consideration, experiment was conducted to determine the best combination factors to obtain optimum hole diameter and surface roughness quality. A methodology was adopted to conduct these experiments in organized method which was the Design of Experiment (DOE) and the data from the experiment was analyzed.

1.1 Background

The aim of this work was to utilize taguchi method to investigate the effects of drilling parameters such as cutting speed (70,90 and 110 m/min), feed (0.1, 0.015, 0.02, 0.45 and 0.8 rev /min) and drill tool diameter (50, 75, 100mm) on positioning accuracy in drilling of OHNS material using solid drill. The analysis of variance (ANOVA), and regression analysis are employed to analyze the effect of drilling parameters on the quality of positioning accuracy. The experimental results are collected and analyzed using commercial software package MINITAB. Linear regression equations are developed with an objective to establish a correlation between the selected drilling parameters with the quality characteristics of the drilled holes. The predicted values are compared with experimental data and are found to be in good agreement.

1.2 Objective

Based on the title and problem statements of this project The main objective of this project are :

1. To study the effect of speed, feed rate , Tool length, and vibration in flood drilling process of aluminum alloy for positioning quality.

2. To analyze the influence slender cutting tool and cutting parameter in dimensional accuracy.

3. To monitor the vibration of cutting tool and the effect of vibration on the accuracy of parts using an accelerometer.

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1.3 Scope of Project

The scope of work was clearly define the specific field of the research and ensure that the entire content of this project is confined the scope. It was began with the literature review. The next step was to perform experimental studies on flood drilling process of aluminum alloys to determined the significant parameters affecting positioning accuracy. The result of the experiment for the positioning accuracy is analyzed under varying cutting speed, feed rates, feed rate and tool length with low and high values setting. Automatically the vibration will read by using the data acquisition system while drilling machine run. The system named as accelerometer had been used to study the effect of vibration of machine tools on dimensional accuracy.

Figure 1.1 : Flow chart represents the scope of work Literature Review on Drilling Process

Quality Characteristic/Parameters Selection

Design of Experiment (DOE) – Full Factorial Experiments

Conduct Experiment - Diameter Hole Accuracy

ANOVA – Predict Optimum Performance

Overall Evaluation Criteria

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1.4 Problem Statement

Based on the literature review on the past research on drilling operations, the following items have been revealed on the processes refer in manufacturing drilling industries. Besides considering the best quality to produce of product and also to fulfill the customer requirement, slender cutting tools and all parameters has been the important factor in understanding and meeting these needs. Usually, manufacturing product always take a lot of times to get the optimum cutting condition because of trial and error for general guide line by pass experience. commonly, machining process practiced by industrial was based on conventional method likes not standard instruction can be used in industry. This has been one of the reasons why the industries could hardly achieve the accurate dimension of products that customers needed. So, for this drilling method using different parameters have been constructed to establish the relationship between the cutting performance and cutting parameters. Here, the research was to establish or guide line quality to expedite the process and employed to investigate the influence of cutting parameters on the positioning accuracy quality.

1.5 Outline of report

Generally, this report was divided into two part which are Projek Sarjana Muda (PSM I) and (PSM II). The total report contains of five chapters, these chapters generally discuses about back ground of study, objectives, problem statement, scope as well as the limitation of the study and research methodology.

Chapter two was the literature review which will done based on journals, books internet resources and also previous studies done related to this topic. Based on information gathered this chapter will discuss the drilling machines, processes cutting tools and operation sequences for drilling machine in order to know the element used to calculate the machining time and cost.

Page | 9 estimate the machining time and machining cost. On this chapter, a detail step by step process to develop the software will be explained.

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CHAPTER 2

LITERATURE

A literature review is a body of text that aims to review the critical points of current knowledge including substantive findings as well as theoretical and methodological contributions to a particular topic. Simai Haji Mati was quoted saying that “literature review should be referred to as reviewing and analyzing the work of literature in

relation to the specified topic in research”.

Literature review is a form of study by reviewing and analyzing the current literature on a specified topic on research. The sources are secondary sources which come from an internet, journals, reference books, magazines and more. This chapter discussed more on the topics which have a great connection to the title of the project. All the reviews in this chapter was much helping in a way to give a good knowledge and has been as a second reference when carrying out the project.

2.1 Drilling