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ABSTRACT: Surface roughness is an important parameter for ensuring that the dimension of geometry is within the permitted tolerance.
The ideal surface roughness is determined by the feed rate and the geometry of the tool. However, several uncontrollable factors
including work material factors, tool angle, and machine tool vibration, may also influence surface roughness. The objective
of this study was to compare the measured surface roughness (from experiment) to the theoretical surface roughness (from theoretical
calculation) and to investigate the surface roughness resulting from two types of insert, ‘C’ type and ‘T’ type. The experiment
was focused on the turning process, using a lathe machine Colchester 6000. The feed rate was varied within the recommended
feed rate range. We found that there were large deviations between the measured and theoretical surface roughness at a low
feed rate (0.05 mm/r) from the application of both inserts. A work material factor of AISI D2 steel that affects the chip
character is presumably responsible for this phenomenon. Interestingly, at a high feed rate (0.4 mm/r), the ‘C’ type insert
resulted in 40% lower roughness compared to the ‘T’ type due to the difference in insert geometry. This study shows that the
geometry of an insert may result in a different surface quality at a particular level of feed rate.
Key wordsSurface roughness-Turning-Insert geometry-Feed rate
Journal of Zhejiang University - Science A: Applied Physics & Engineering 11(12):966-971. · 0.53 Impact Factor