Sains Malaysiana 41(12)(2012): 1605–1612

 

Penentuan Faktor yang Mempengaruhi Daya dan Taburan Tegasan Semasa Pemesinan

Besi Tuangan Mulur (FCD 500) Secara Simulasi

(Determination of Factors that Affect Force and Stress Distribution During Machining

Ductile Cast Iron (FCD 500) by Simulation)

 

Aminah Ishak, Jaharah A. Ghani* & Che Hassan Che Haron

Jabatan Kejuruteraan Mekanik dan Bahan, Fakulti Kejuruteraan dan Alam Bina

Universiti Kebangsaan Malaysia, 43600 Bangi, Malaysia

 

Diserahkan: 13 Februari 2012 / Diterima: 6 Ogos 2012

 

 

ABSTRAK

Kaedah unsur terhingga (FEM) berdasarkan pemodelan dan simulasi proses pemotongan telah menarik minat ramai penyelidik secara berterusan untuk mengkaji lebih mendalam terutamanya mengenai penjanaan daya dan suhu di dalam zon pemotongan yang sebelum ini tegasan tidak boleh diukur secara langsung. Dalam kajian ini, simulasi proses pemotongan ortogon besi tuang mulur (FCD 500) menggunakan mata pemotong karbida pada pelbagai keadaan angin sejuk telah dikaji. Perisian DEFORM digunakan untuk menjalankan simulasi proses pemotongan ortogon dengan laju pemotongan (100-300 m/min), kadar suapan (0.15-0.35 mm/pus), kedalaman pemotongan (0.2-0.8 mm) dan suhu angin sejuk (2o -25oC). Mata pemotong mempunyai jejari hidung mata pemotong 0.4 mm, sudut sadak, α =5o dan sudut kelegaan, β = 7o. Reka bentuk uji kaji adalah menggunakan kaedah Taguchi dalam tatasusunan ortogon L9, nisbah S/N dan analisis Pareto ANOVA digunakan untuk menganalisis kesan parameter pemotongan terhadap hasil pemesinan iaitu daya, tegasan dan suhu semasa pemesinan. Keputusan menunjukkan kadar suapan memberikan pengaruh yang paling tinggi (96.12%) terhadap daya pemotongan. Tegasan pemotongan paling dipengaruhi oleh kadar suapan iaitu 78.87%. Kajian ini telah membuktikan, banyak masa, kos dan tenaga dapat dijimatkan dalam mengkaji kebolehmesinan sesuatu bahan secara simulasi berbanding dengan kaedah eksperimen, di samping keputusan yang tepat diperoleh.

 

Kata kunci: Alat pemotong karbida; besi tuangan mulur (FCD 500); daya pemotongan; tegasan pemotongan

 

ABSTRACT

Finite element method (FEM) based on modeling and cutting process simulation has continuously attracted many researchers to study in more detail especially on force generation and temperature in cutting zones, in which previously stress could not be measured directly. In this study, orthogonal cutting process simulation of ductile cast iron (FCD 500) using carbide cutting tool in various chilled air condition was studied. DEFORM software was used to carry out the cutting process simulation at various cutting speed (100-300 m/min), feed rate (0.15-0.35 mm/rev), depth cutting (0.2-0.8 mm) and chilled air temperature (2o -25oC). The cutting tool has tool nose radius of 0.4 mm, rake angle, α =5o and clearance angle, β= 7o. Experimental design used was Taguchi method using orthogonal L9 array, S/N ratio and Pareto ANOVA analysis were used to analyse the cutting parameters effect on machining response of cutting force, stress and temperature generated during the machining process. The results showed that the feed rate has the highest influence (96.12%) on the cutting force. Cutting stress was mostly influenced by feed rate (78.87%). This simulation studies proved that great deal of time, cost and energy can be saved in study the machinability of certain material using simulation compared with experimental method, besides a right decision can be achieved.

 

Keywords: Carbide cutting tool; cutting force; cutting stress; ductile cast iron (FCD 500)

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*Pengarang untuk surat-menyurat; email: jaharah@eng.ukm.my