CHAPTER 1 INTRODUCTION 11 Introduction Manufacturing process can Essay

CHAPTER 1 : INTRODUCTION

1.1 Introduction

Manufacturing process can be defined as a worldwide activities which is taking place when the industrial revolution during the late 19th century. It has been implemented due to the high demand and to provide huge scale productions of the products created. Today, manufacturing process has been growth and undergoes changes due to the innovation of technology, materials and other aspects. Some challenges and problems that might be faced by the manufacturing company are to create and produce a large amount of products by decreasing the amount of materials, labors and energy.

This is because, the manufacturing process is input-output system which is manufacturing resources for example materials and energy are transform into semi products or products.

In the manufacturing process, machine tools is one of the important components in order for the manufactures to create and produce the products. Machine tools is power operated, non- portable and valuable machine which can make a multiple machining processes by removing an excess materials away from a pre-shaped blank by using an appropriate cutting tools.

The example of cutting tools which have been used today are lathe, milling, shaping and many more. In addition machine tools are also called as machine but it is not vice-versa.

Cutting tools are defined as small device which have a one or more wedge shaped and sharp cutting edge. The function of this components is to help the shearing process when performing the metal cutting. Cutting tools are basically function to removes (shears off) materials from the work piece. Severely it is located and mounted at the appropriate location on the machine tools. For the features and shaped of the cutting tools it is usually varies based on the proposed performance and essential machining operation. On the motion which is required for cutting, it is provided by machine tools instead of cutting tools.

1.2 Problem Statement

Machining cost is one of the important component factors when performing the manufacturing process. The aim of this research is to test multilayer coating materials on the brand new geometry of cutting tool called as dual point cutting tool which can be used for the turning operation of free cutting steel (AISI 12L14). By creating a brand new multilayer carbide tools, it will help the manufactures to reduce the machining cost by increasing the production volume and rate, increasing good surface quality of machined parts and this will give the positive effect and help to reduce the manufacturing costs.

1.3 Aims and Objectives

1. To study the surface roughness, cutting force and tool wear of AISI 12l 14 by using new cutter design with different type of multilayer coating materials.

2. To compare the different type of coating materials on the new cutter design in terms of cutting tool performance.

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1. Type of materials used to coat the multilayer carbide tools which is TiN, TiCN, TiAIN and CrN.

2. Type of machine used for turning operation.

3. The parameters to determine the best coated materials for cutting tools performance which is tool wear progression, cutting tool forces, and surface finishing.

4. Different thickness for the coated materials.

5. The final results of the research which is to determine the best coated materials for cutting tool performance.

1.5 Significant of research

Coated tools and high speed machining are usually used in processing the free cutting steels in order to increase the efficiency and to decrease the tool during the actual production operation. The significant of this research is to study about the metal cutting technology thus to improve the cutting tools materials, surface characteristic, applying the advance coating and many more. This is because most of the cutting metals today used about 90 percent of cemented carbide. The reason why new cutting tools materials is needed to use is because, it is to improve wear circumstances and hardness thus it will help to reduce the cost by increasing the productivity and extending the tool life. The benefits of advance coating used are low friction at the chip tool, high hot hardness, low amount of friction and higher thermal and chemical stability. In order to improve their performance on cutting tools, the physical vapor deposition (PVD) is used to create variety of the surface coatings.

1.6 Project outline

This paper consist of 5 chapters starting from chapter 1 until chapter 5. For chapter 1, it is focused on the general information and the aim of this research. In addition, problem statement, objective, scope and significant of the project were also identify and made in this chapter.

For chapter 2, it is more focusing on the research for the literature review based on the previous established research and journals. This review in on the research which used and have the similar method related to this project.

Chapter 3 was about the discussion on dealing with the complete explanation of the methodology used. The example of data sheet and table for the results were provided and this sample will be used to analysed and present the data. Furthermore, the planning for the resources, mathematical model and expected outcomes were also shown in this chapter.

Meanwhile for the chapter 4, it contain about the data and results from the experiment which lead to the discussion. All the data will be analysed based on the selected parameters and will be explain completely in this chapter.

Lastly which is the chapter 5, it will be the conclusion about this paper. All the details and research about this paper will be summarized and the recommendation for the usage in the future were also discussed in this chapter.

1.7 Gantt Chart

In the Gantt chart for EFYP1 and EFYP 2, two type of status which is plan and actual task has been done. The plan status is the progress of the task while the actual status is referred to the actual task that has been done and completed. This Gantt chart were decided and scheduled based on the academic planner from the University and follows the EFYP1 report submission and presentation.

Based on the EFYP1 Gantt chart, it shows that there are lot of time used at the chapter 2 compared to chapter 1 and chapter 3 because this is the most difficult part on the thesis. Student need to identify and find the suitable journals based on the topic of the research. Besides that, the objective, problem statement and methodology of this research need to be monitored time by time in order to ensure the results is achieved at the expected time.