UNIVERSITI TEKNIKAL MALAYSIA MELAKA OPTIMIZATION OF MACHINING PARAMETERS IN TURNING PROCESS OF ALUMINUM ALLOY 6063 This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Robotic and Automation) with Honours. by LEE CHEE YOONG FACULTY OF MANUFACTURING ENGINEERING 2010
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
OPTIMIZATION OF MACHINING PARAMETERS IN TURNING
PROCESS OF ALUMINUM ALLOY 6063
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotic and Automation) with Honours.
by
LEE CHEE YOONG
FACULTY OF MANUFACTURING ENGINEERING
2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Optimization of Machining Parameters in Turning Process of Aluminum Alloy
6063
SESI PENGAJIAN: 2009/10 Semester 2
Saya LEE CHEE YOONG
mengaku membenarkan tesis Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal
Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan ini 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)
(TANDATANGAN PENULIS)
Alamat Tetap:
No. 9, Lorong Kledang Utara 1,
31450, Menglembu,
Ipoh, perak
Tarikh: _________________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak
berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan ini perlu
dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Optimization of Machining Parameters in
Turning Process of Aluminum Alloy 6063” is the results of my own research except as
cited in references.
Signature : ………………………
Author’s Name : LEE CHEE YOONG
Date : 9 APRIL 2010
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 (Robotic and Automation) with Honours. The member of the supervisory
committee is as follow:
(Signature of Supervisor)
………………………………….
(Official Stamp of Supervisor)
OPTIMIZATION OF MACHINING PARAMETERS IN
TURNING PROCESS OF ALUMINUM ALLOY 6063
LEE CHEE YOONG
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
i
ABSTRACT
This report presents an optimization of machining parameters in turning process of
Aluminum alloy 6063 T6. OKUMA LCS-15 horizontal turning machines have been
used to run the experiments on Aluminum alloy 6063 T6. Aluminum is widely used in
automotive industry, aerospace applications, architectural applications and others. The
main objective of the research was to determine the effect of different parameters setting
such as depth of cut, feed rate and cutting speed on surface roughness and hardness. In
this research, the RSM (response surface methodology) method with Central Composite
Design (CCD) was used to design the experiment and 20 trials were conducted. The
machined surface was checked by using portable surface roughness tester and hardness
was measured by using Digital Micohardness tester. The quadratic model was selected
in the analysis of variance (ANOVA) and the model graph revealed the interaction
between the three controllable parameters. The analysis revealed that cutting speed was
the significant effect to the surface roughness followed by the feed rate while depth of
cut was less effect. The best surface finish can be obtained with the combination of
lowest cutting speed and feed rate. Besides, the numerical optimization method was
employed in the optimization and the best predicting setting was depth of cut 0.69 mm,
feed rate 0.09 mm/rev and cutting speed 153.14 m/min. The average deviation
percentage value was 54.84%. In the experiment, the hardness was influenced by the
cutting speed and feed rate. The highest of cutting speed and feed rate will cause
hardness decreasing.
ii
ABSTRAK
Laporan ini menerangkan pengoptimuman parameter dalam proses pemesinan larik pada
Aluminium alloy 6063 T6. Okuma SKB-15 mesin larik melintang digunakan untuk
menjalankan eksperimen pada bahan kerja Aluminium 6063 T6. Aluminium banyak
digunakan dalam industri automotif, angkasa aplikasi, arsitektur aplikasi dan lain-lain.
Objektif utama dari penelitian ini adalah untuk menentukan kesan daripada tatacara
parameter yang berbeza seperti kedalaman pemotongan, kadar suapan dan kelajuan
dalam pemotongan ke atas kekasaran permukaan dan kekerasan. Dalam kajian ini,
kaedah RSM (response surface methodology) bersama dengan Central Composite
Design (CCD) digunakan untuk merancang percubaan bagi eksperimen ini dan 20 uji
kaji telah dijalankan dengan merujuk kepada jadual matriks. Permukaan yang telah
dimesin diperiksa dengan menggunakan alat uji kekasaran permukaan mudah alih dan
kekerasan diukur dengan menggunakan Digital Micohardness tester. Model kuadratik
dipilih dalam analisis varians (ANOVA) dan model grafik mendedahkan interaksi antara
tiga parameter yang dikendalikan. Analisis menunjukkan bahawa kelajuan pemotongan
adalah pembolehubah yang signifikan terhadap kekasaran permukaan diikuti oleh kadar
suapan sementara kedalaman pemotongan adalah kurang signifikan. Permukaan terbaik
boleh didapati dengan kombinasi kelajuan pemotongan dan kadar suapan dengan nilai
yang terendah. Selain itu, kaedah pengoptimuman berangka telah digunakan dalam
optimasi dan tatacara yang terbaik untuk meramalkan adalah kedalaman pemotongan
0.69 mm, kadar suapan 0.09 mm/rev dan kelajuan pemotongan 153.14 m / min. Nilai
rata-rata deviasi peratusan adalah 54.84%. Dalam eksperimen ini, kekerasan telah
dipengaruhi oleh kelajuan pemotongan dan kelajuan secara maklumnya. Peningkatan
kelajuan pemotongan dan kadar suapan secara maklum akan menyebabkan penurunan
kekerasan.
iii
DEDICATION
To my lovely family and fellow friends that accompanying me along the difficult
pathway in my university life, thanks for your help and support.
iv
ACKNOWLEDGEMENT
I would like to take this opportunities to express my sincere thank to all people that
helping me to succeed this project. Firstly, I would like to thank to my project supervisor,
Ms LIEW PAY JUN. Without her guidance, I would not be succeeding to accomplish
my project. Once again thanks for her guidance, advice, and help in this project.
Secondly, I would like to thank to Manufacturing Engineering Laboratory of Universiti
Teknikal Malaysia Melaka (UTeM) for providing me the equipments and machines.
Moreover, I would like to thank to Mr. Farihan for giving me lot convenience in using
the equipments in the Laboratory. Besides, I would like to thank to laboratory of
Universiti Tun Hussein Onn Malaysia (UTHM) for providing equipments to accomplish
my project.
Furthermore, special thanks to all my friends Lee Weng Sum, Liew Tong Ken and Tan
King Hwang. They had giving me advice, ideas, comments and sharing their time to
completed my project.
Lastly, unforgettable I would like to thank to my parents and family that always give me
encourage and supports to me. I was very appreciating the supports they give to me with
heartfelt.
v
TABLE OF CONTENT
Abstract i
Abstrak i i
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures x
List Abbreviations xii
1. INTRODUCTION 1
1.1 Introduction 1
1.2 Problem statement 3
1.3 Objective 3
1.4 Scope 3
1.5 Importance of study 4
1.6 Result expected 4
2. LITERATURE REVIEW 5
2.1 Turning Process 5
2.2 Parameters 6
2.2.1 Cutting Speed 7
2.2.2 Feed Rate 8
2.2.3 Depth of Cut 8
2.3 Aluminum alloy 6063 9
2.4 Cutting Tool Material 9
2.5 Responses of Turning Process 1 1
2.5.1 Surface Roughness 1 2
2.5.2 Surface Texture 1 3
vi
2.5.3 Vickers Hardness Test 1 4
2.6 Design of Experiment 1 6
2.6.1 Response Surface Methodology 1 6
2.6.1.1 Central Composite Design (CCD) 1 7
2.6.1.1.1 Factorial Points 1 7
2.6.1.1.2 Star or Axial Points 1 8
2.6.1.1.3 Center Points 1 8
2.7 Summary of Journal 1 9
2.8 Conclusion 2 3
3. RESEARCH METHODOLOGY 2 4
3.1 Flow chart of study 2 5
3.2 Stage 1: Define the objective of the experiment 2 6
3.3 Stage 2: Determine the parameters speed at low level and high level 2 6
3.4 Stage 3: Identify the appropriate responds variable 2 7
3.5 Stage 4: Design of experiment matrix 2 7
3.6 Stage 5: Preparation of the experiment 2 8
3.6.1 OKUMA LCS-15 horizontal machines 2 8
3.6.2 Abrasive cutting machine 2 9
3.6.3 Workpiece preparation 3 0
3.6.3.1 Material properties 3 1
3.6.4 Cutting inserts 3 2
3.6.5 Tool Holder 3 3
3.7 Stage 6: Run the experiment 3 3
3.7.1 Surface Roughness Testing 3 5
3.7.2 Cutting Process (Cross Section) 3 6
3.7.3 Mounting Process 3 7
3.7.4 Hardness Test 3 9
3.8 Stage 7: Analysis the Results 4 0
3.9 Stage 8: Conclusion 4 0
3.10 Gantt chart for PSM 1 4 1
vii
3.11 Gantt chart for PSM 2 4 2
4. RESULTS AND DISCUSSION 4 3
4.1 Results 4 3
4.2 Analysis of Surface Roughness 4 5
4.2.1 Transformation 4 5
4.2.2 Fit Summary 4 6
4.2.2.1 Sequential Model Sum of Squares [Type I] 4 6
4.2.2.2 Lack of Fit Tests 4 8
4.2.2.3 Model Summary Statistics 4 8
4.2.3 ANOVA 4 9
4.2.3.1 Backward Elimination 5 1
4.2.3.2 Regression Statistics 5 2
4.2.4 Model Diagnostics Plots 5 3
4.2.5 Model Graph 5 5
4.2.5.1 Effect of Feed Rate on Surface Roughness 5 5
4.2.5.2 Effect of Cutting Speed on Surface Roughness 5 7
4.2.5.3 Effect of Depth of Cut on Surface Roughness 6 0
4.2.5.4 Perturbation Graph 6 1
4.2.5.5 Effect of Interaction between Cutting Speed and Feed Rate
on Surface Roughness 6 2
4.2.5.6 Effect of Interaction between Depth of Cut and Feed Rate
on Surface Roughness 6 3
4.2.5.7 Cube Plot 6 4
4.3 Optimization 6 5
4.4 Confirmation Run 6 8
4.4.1 Average Deviation Percentage Value 7 0
4.5 Hardness Test 7 1
5. CONCLUSION AND RECOMMENDATIONS 7 3
5.1 Conclusion 7 3
viii
5.2 Recommendations 7 4
REFERENCES 7 5
APPENDICES
A Results of surface roughness
ix
LIST OF TABLES
2.1 Summary of journal 1 9
3.1 Factors and their entire unit and levels 2 6
3.2 Input variables from RSM software 2 7
3.3 Specification of OKUMA LCS-15 horizontal turning machines 2 9
3.4 Chemical composition 3 1
3.5 Mechanical properties 3 2
3.6 Physical properties 3 2
3.7 Constant parameter 3 4
4.1 Surface roughness value with different factor 4 4
4.2 Sequential Model Sum of Squares [Type I] 4 7
4.3 Lack of Fit Test 4 8
4.4 Model Summary Statistics 4 8
4.5 Analysis of variance table [Partial sum of squares – Type III] 5 0
4.6 Analysis of variance table [Partial sum of squares – Type III] after removing
the significant model 5 2
4.7 Regression statistic 5 2
4.8 Solution Value generates by Design Expert software 6 7
4.9 Optimization value for surface roughness 6 8
4.10 Average Deviation Percentage Value 7 0
4.11 Hardness test value with difference distance 7 1
x
LIST OF FIGURES
2.1 The hardness of various cutting-tool materials as a function of
temperature (hot hardness) 1 0
2.2 Ra of a surface profile P on a sampling length L 1 3