MONITORING TOOL WEAR PROCESS IN TURNING MACHINE USING ACOUSTIC EMISSION TECHNIQUE AZLAN BIN MOHD SAINI BACHELOR OF ENGINEERING UNIVERSITI MALAYSIA PAHANG 2010
MONITORING TOOL WEAR PROCESS IN TURNING MACHINE USING ACOUSTIC EMISSION TECHNIQUE AZLAN BIN MOHD SAINI Report submitted in partial of the requirements for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG DECEMBER 2010
UNIVERSITI MALAYSIA PAHANG BORANG PENGESAHAN STATUS TESIS JUDUL: Saya MONITORING TOOL WEAR PROCESS IN TURNING MACHINE USING ACOUSTIC EMISSION TECHNIQUE SESI PENGAJIAN: 2010/2011 AZLAN BIN MOHD SAINI (850907-08-5227) (HURUF BESAR) mengaku membenarkan tesis (Sarjana Muda/Sarjana /Doktor Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Malaysia Pahang (UMP). 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: NO 37, MMINORAZEANSUHAILA BINTI LOMAN JALAN WM 3A/10, BANDAR BEHRANG 2020, ( Nama Penyelia ) 35950 TANJUNG MALIM, PERAK. Tarikh: 6 DECEMBER 2010 Tarikh: : 6 DECEMBER 2010 CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah doktor Falsafah dan Sarjana secara Penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM).
i UNIVERSITI MALAYSIA PAHANG FACULTY OF MECHANICAL ENGINEERING I certify that the thesis entitled Monitoring Tool Wear Process In Turning Machine Using Acoustic Emission Technique is written by Azlan Bin Mohd Saini. I have examined the final copy of this thesis and in my opinion; it is fully adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering. I herewith recommend that it be accepted in fulfillment of the requirements for the degree of Bachelor of Mechanical Engineering with Automotive Engineering. DR. YUSNITA RAHAYU Examiner Signature
ii SUPERVISOR S DECLARATION I hereby declare that I have checked this thesis and in my opinion, this thesis is adequate in terms of scope and quality for the award of the degree of Bachelor of Mechanical Engineering with Automotive Engineering. Signature: Name of Supervisor: MIMINORAZEANSUHAILA BINTI LOMAN Position: LECTURER Date: 6 DECEMBER 2010
iii STUDENT S DECLARATION I hereby declare that the work in this thesis is my own except for quotations and summaries which have been duly acknowledged. The thesis has not been accepted for any degree and is not concurrently submitted for award of other degree. Signature: Name: ID Number: AZLAN BIN MOHD SAINI MH08018 Date: 6 DECEMBER 2010
viii TABLE OF CONTENTS Page EXAMINER DECLARATION SUPERVISOR DECLARATION STUDENT DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATION i ii iii iv v vi vii viii xi xii xiii CHAPTER 1 INTRODUCTION 1.1 Background of Study 1 1.2 Problem Statement 2 1.3 Research Objective 3 1.4 Scopes 3 CHAPTER 2 LITERATURE REVIEW 2.1 Overview of Acoustic Emission 4 2.1.1 Implementation of Acoustic Emission 7 2.2 Turning Process 8 2.2.1 Process Cycle 11 2.2.2 Cutting Parameters 12 2.2.3 Operations 13 2.2.3.1 External Operation 14 2.2.3.2 Internal Operation 14
ix 2.3 Tool Wear 15 2.3.1 Carbon Steels 17 2.3.2 High Speed Steel (HSS) 18 2.3.3 Cast Cobalt Alloy 18 2.3.4 Carbides 19 2.3.5 Coatings 19 2.3.6 Cermets 20 2.3.7 Ceramics 20 2.3.8 Cubic Boron Nitride (cbn) 21 2.3.9 Diamond 21 CHAPTER 3 METHODOLOGY 3.1 Introduction 22 3.2 Project Methodology Flow Chart 23 3.3 Cutting Speed Calculation 26 3.4 Material Selection 27 3.5 Process Data Acquisition 28 CHAPTER 4 RESULT AND DISCUSSION 4.1 Introduction 32 4.2 Low cutting Speed 32 4.3 Medium Cutting Speed 36 4.4 High Cutting Speed 40 4.5 Discussion 44 CHAPTER 5 CONCLUSION AND RECOMMENDATION 5.1 Conclusion 49 5.2 Recommendation 49 REFERENCES 51
x APPENDICES A Table with Difference Materials Complete with Properties 53 B Data Acquisition and Analysis 54 C1 Chips Form Lathe Machining 55 C2 Machines and Equipments 56
xi LIST OF TABLES Table No. Title Page 2.1 Capability of Turning 10 3.1 Machine Specification 24 3.2 Turning Operation Recommendation 26 4.1 Data Experiment for Lower Cutting Speed 32 4.2 Data Experiment for Medium Cutting Speed 36 4.3 Data Experiment for High Cutting Speed 40 4.4 Acquisition Data from Difference Cutting Speed 45
xii LIST OF FIGURES Figure No. Page 2.1 Acoustic Emission signal features 5 2.2 System of Acoustic Emission 6 2.3 Manual lathe machine 9 2.4 Axial depth of cut and radial depth of cut 13 2.5 Cutting tool terminology 16 2.6 Various tool bits, carbide inserts and holders 17 3.1 Flowchart for monitoring tool wear process 23 3.2 Experiment set-up 25 3.3 Cutting material process 28 3.4 Position of sensor 39 3.5 Scheme of the monitoring system 30 4.1 Crater wear on cutting tool with lower cutting speed condition 33 4.2 Amplitude against frequency for feed 0.22mm/rev 34 4.3 Amplitude against frequency for feed 0.28mm/rev 35 4.4 Crater wear on cutting tool with medium cutting speed condition 36 4.5 Amplitude against frequency for feed 0.22mm/rev 38 4.6 Amplitude against frequency for feed 0.28mm/rev 39 4.7 Crater wear on cutting tool with high cutting speed condition 40 4.8 Amplitude against frequency for feed 0.22mm/rev 42 4.9 Amplitude against frequency for feed 0.28mm/rev 43 4.10 Frequency against tool wear 46 4.11 RMS against cutting speed 47 4.12 Energy against cutting speed 48
xiii LIST OF ABBREVIATIONS AE Al 2 O 3 cbn CNC CS CVD D FYP GRP HP HSS IPM IPR IPT LPG PCD PVD RMS RPM SFM Si 3 N 4 SiC SMA TiC ZrO 2 Acoustic Emission Aluminium Oxide Cubic Boron Nitride Computer Numerical Control Cutting Speed Chemical Vapour Diameter Final Year Project Glass Reinforced Plastic Horse Power High Speed Steel Inches per Minute Inches per Revolution Inches per Tooth Liquid Petroleum Gas Polycrystalline Diamond Physical Vapour Deposition Root Mean Square Revolutions per Minute Surface Feet per Minute Silicon Nitride Silicon Carbide Shape Memory Alloys Titanium Carbide Zirconium Oxide