This paper presents the effect of drilling parameters on surface roughness and surface appearance by applying response surface method (RSM). The mathematical model for correlating the interactions of drilling parameters such as spindle speed, feed rate and drill diameter on surface roughness was developed. RSM methodology was used as it is a technique that most practical and effective way to develop a mathematical model. In addition, this method also can reduce trial and error in experiment. Since the number of factors are three; spindle speed, feed rate and drill diameter, by applying RSM the total numbers of experiment involved are 20 experimental observations. From the experimental result, it is found that the minimum surface roughness on the hole was 1.06 mm from combination of 2000 rpm spindle speed, 78 mm/min feed rate and 2.5 mm drill diameter. While the maximum surface roughness 2.59 mm was the combination of 250 rpm spindle speed, 153 mm/min feed rate and 3.5 mm drill diameter. A mathematical equation was developed with percentage of error are 0% to 29%. Thus, from the result we understand that to find the smooth surface in drilling process, it needs higher spindle speed with lower feed rate and smaller diameter.
The effect of maleated polypropylene (MAPP) as binder on the mechanical properties of kenaf fibre/polypropylene (KF/PP) composites is studied. Ratios between kenaf fibre and PP having 10:90, 30:70 and 50:50 in weight ratio were selected. Further, MAPP having 1, 3 and 5 percent in percentage of weight ratio was mixed in KF/PP composites. Hot press machine was used to produce tensile test samples of KF/PP composites. The mechanical properties that are tensile strength, tensile modulus and elongation at break of KF-PP composites were obtained from tensile test result. It is found that the tensile strength and tensile modulus increase with increasing the kenaf fibre loading and higher percentage of MAPP. Further, the elongation at break for KF/PP composites shows lower result when increasing of kenaf fibre loading. However, when percentage of MAPP added in KF/PP composites increases, the elongation at break increased slightly. Thus, result shows that kenaf fibre/PP composites with binder were better in tensile strength, tensile modulus however the elongation at break shows weak result unless the binder was added.
Warpage deflection is one of the common pitfalls in plastic injection moulding which is always affected the quality and accuracy of the plastic products. It occurs due to the influences of mould temperature during injection moulding process and it is related to the number of cooling system existed in the mould. Therefore, this paper studies the effect of cooling channels on warpage of dumbbell plastic part having different number of cooling channel using Moldflow software. Warpage analysis was run using four and eight cooling channels. Parameters involved in this study are injection time, packing time, melt temperature and mould temperature. The result of warpage from simulation analysis was projected on the graphic having different colour which is presented the actual value of warpage. It is found from warpage simulation result that the maximum warpage for four cooling channels is 1.283mm and the maximum warpage for eight cooling channels is 1.280mm. It shows that the increasing of the number of cooling channel from four to eight channels in the injection mould reduces the warpage deflection about 0.2%. Thus, the result shows that the number of cooling system in the mould plays an important role on the quality of plastic part during injection moulding process.
Polyetheretherketones (PEEK) have been widely used as biomaterials for trauma, orthopedics and spinal implants. However, machining of this material poses several challenges such as rough machined surface which can affect the implant functional application. This research attempts to optimize the machining parameter (cutting speed, feed rate and depth of cut) for effectively machining Polyetheretherketones (PEEK) implant material using carbide cutting tools. Apart from optimizing machining parameters, effects of annealing condition on PEEK towards surface qualities are discuss. Response Surface Methodology (RSM) technique was used to evaluate the effects of the parameters and their interaction towards the ability of the optimum conditions. Based on the analysis results, the optimal machining parameter to obtain the smallest surface roughness values were by using spindle speed of 5754 rpm, feed rate of 0.026 mm/tooth and 5.11 mm depth of cut for un-annealed PEEK. As for the annealed PEEK to get the smallest surface roughness values were by using spindle speed of 5865 rpm, feed rate of 0.025 mm/tooth and 2 mm depth of cut.
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