EFFECT OF CUTTING VARIABLES ON

THE SURFACE FINISH OF DEAD MILD

STEEL (DMS)
Jewo O.A. and Ebojoh E.

Lecturer, Department of Mechanical Engineering, Petroleum Training Institute, Effurun, Delta State
Lecturer, Department of Production Engineering University of Benin, PMB 1154, Benin City, Nigeria

ABSTRACT: An experimental study on the effect of cutting parameters (spindle speed, feed rate and depth of cut)
on surface finish of dead mild steel (DMS) is presented. In machining operation, the quality of surface finish is an
important factor in many turned workpiece; it either improves or reduces the value of a given machined component.
In this study, the specimen was cut into required piece (50x200mm) and turning operation was done using a tungsten
carbide tip tool. Graphical method was used to evaluate the effect of these cutting parameters. The result obtained
show that feed rate of 0.20mm/min has the most effect on the surface finish. The combination of minimum depth of
cut (0.25mm) and maximum constant spindle speed of 700rpm gave a minimum effect on the surface finish with Ra
value of 1.1µm. However, spindle speed of 450rpm and depth of cut 0.25mm gave a maximum roughness value of
2.8µm.

KEY WORDS: Roughness value, Depth of cut, feed rate, Spindle speed, Mild steel

I.INTRODUCTION

Steel has a major influence in our lives, the cars we drive, the homes in which we live and countless other facts in
between. Steel is used in the electric power line tower, natural gas pipelines, machines tools, military weapons and
so on. Steel is by far the most important, multifunctional and most adaptable materials compared to other materials
of its type. It has low production cost and it is environment friendly because it is recyclable. Steel production is 20
times higher as compared to production of all non- ferrous. Steel is widely used in manufacturing process to produce
various products. Metal cutting on the other hand is an industrial process in which metal parts are shaped or removal
of unwanted materials. It is one of the most important and widely used manufacturing processes in engineering
industries. In metal cutting, the output quality is of great important. A significant improvement in output quality can
be obtained by optimizing the cutting parameters. Optimization of parameters does not only improve output quality
but also ensures low cost manufacturing.
Product quality is mostly dependent on the surface finish. Decrease of surface roughness quality also leads to
decrease in product quality in the field of manufacturing, especially engineering, the surface finish can be a
considerable factor which can affect the functioning of a component and possibly its cost. Surface roughness has
been receiving attention for many years in the machinery industries. It is an important design feature in many
situations such as arts subjects and fatigue loads, precision fits, farter holes, and so on.

II. SIGNIFICANCE OF THE STUDY

This study is to ascertain the cutting variable that has the least or most effect on the surface roughness of dead mild
steel. This will ensure better quality product with good aesthetics characteristics.

III. LITERATURE SURVEY

A study on the correlation among the cutting parameters, surface roughness and cutting forces in turning process on
Aluminium alloy where full factorial method was used to carryout experimental investigations and statistical
analysis was performed using MINITAB 16 software[1]. The results of the study shows that feed rate affect surface
roughness (70.35%) most while depth of cut (85.37%) being the most influencing parameter on cutting forces.
Furthermore, in a recent study full factorial method was used to evaluate the effect of cutting variables on surface
roughness during turning of ASISI 304L alloy steel with coated carbide [2].The input variables used were cutting
speed, feed rate and depth of cut. Minitab17 software was used to conduct analysis of variance test on the data. The
result shows that feed rate has the most significant effect on surface roughness with 79.86% and the relationship
between feed rate and cutting speed at constant depth of cut shows that as feed rate increase for every cutting speed,
the surface roughness increases.

In the same vein, Vikram et al [3] carried out a study on the prediction of optimality and effect of machining
parameters on surface roughness based on Taguchi design of experiments. This work focused on surface roughness
produced in speed machining on lathe. Machining was carried out on AISI 1040 steel material using coated carbide
inserts and high speed steel (HSS) tools. Spindle speed and feed rate were chosen as control factors. These control
factors were adopted to analyze significance and contribution on the surface roughness of the machined parts.
Taguchi method based on orthogonal Arrays was used to design the experiments. Analysis of variance (ANOVA)
was then used to analyze the influences and contribution of the machining parameters on the surface roughness
values based on F-Statistic Test. The result of this study from ANOVA test and % contribution evaluation show that
spindle speed seemed to be very highly significant predominant factor in producing the surface roughness while
machining with both type of tools. Also an investigation was carried out on the effect of cutting parameters (cutting
speed, depth of cut and feed) in turning off mild steel and aluminium to achieve better surface finish and to reduce
power requirement by reducing the cutting forces involved in machining [4]. The experimental layout was designed
based on the 2^k factorial techniques and analysis of variance (ANOVA) was performed to identify the effect of
cutting parameters on surface finish and cutting forces are developed by using multiple regression analysis. The
coefficients were calculated by using regression analysis and the model is constructed. The model is tested for its
adequacy by using 95% confidence level. By using the mathematical model the main and interaction effects of
various process parameters on turning was studied.

The optimization of machining parameters based on surface roughness prediction for AA6061 using response
surface method. The study includes the cutter flutes in addition to cutting speed, feed rate and depth of cut.
Response Surface Model (RSM) was adopted to establish the relationship model between the surface roughness and
the parameters using Minitab16 software [5]. The sensitivities of the surface roughness to the parameters were then
analyzed based on analysis of variance (ANOVA). The result shows that cutter flutes has high significant influence
on surface roughness followed by feed rate and depth of cut, while cutting speed has the less significant influence.
Further an experimental study on the effect of cutting parameters on surface finish of stainless steel and aluminium
was also conducted [6]. The study was carried out in order to find the optima control parameters that give the
minimum surface roughness. In their work, the analysis of effect of process parameters; cutting speed, feed rate and
depth of cut, were considered and graphical method was used to determine the parameters with the minimum effect
on the surface finish of the specimen.

Some authors in their research [7] showed that the factors that influence the surface roughness level of carbon steel
material are spindle speed followed by feed rate and depth of cut. To get the result of smooth surface roughness with
Ra value about 1.18 μm, setting parameter used is spindle speed 600 rpm, 130 m/min feed rate and 1.5 mm cutting
depth. To obtain a rough surface roughness of about 6.25 μm, the setting parameters used are 400 rpm spindle speed,
240 m/min feed rate, and 1.0 mm cutting depth. Also [8] uses the combination of signal to noise and analysis of
variance were used in this investigation, besides, the model adequacy examination was carried out through residual
analysis. The cutting speed, feed rate and regression model were statistically significant for hardness, also a
moderate increase of it was found. On the other hand, feed rate was statistically significant factor for surface
roughness and, its lowest value for the lower feed rate and the medium cutting speed was observed. Besides, the 75
% of the data values are less than or equal to 3,2 μm, therefore, the grinding operation could be avoided. The taguchi
technique and the analysis of variance (ANOVA) were employed to investigate the effect of the turning parameters
on Metal Removal Rate (MRR) and Tool Wear Rate (TWR). The LARGER THE BETTER signal to noise (S/N)
ratio based on the Taguchi technique was applied for MRR while the LOWER THE BETTER S/N ratio was applied
for TWR[9].
 IV. METHODOLOGY

Material
The workpiece material used in this study is low carbon steel (dead mild steels), also known as black mild steel has
a dark colour as the name implies and is different from bright mild steel due to its percentage carbon and it varies
from 0.05-0.15%. It is used for making various components like sheets, ships, wire, or rod. This percentage of
carbon gives the dead mild steel the properties of ductility and formability. Table 1 shows the various composition
of low carbon steel (www.matweb.com/searcg/datasheet.aspx accessed 2020)[10].
Table 1: Composition of Low Carbon Steel
Element (%)
Aluminum, Al 0.0100 - 1.50
Boron, B 0.000500 - 0.00600
Carbon, C 0.00300 - 0.800
Chromium,Cr 0.200 - 10.0
Cobalt, Co 7.50 - 12.0
Copper, Cu 0.0200 - 1.50
Iron, Fe 63.0 - 100
Lead, Pb 0.150 - 0.360
Manganese, Mn 0.100 - 2.20
Molybdenum, Mo 0.0800 - 4.80
Nickel, Ni 0.0300 - 18.5

The specimen dimension used for dead mild steel material was 50mm diameter and 200mm length, this is done so as
to maintain a ratio of cylindrical turning length to the initial diameter of workpiece at 4 in order to ensure the
required stiffness of chuck/workpiece/cutting force (Lawal 2016). The cutting tool material used for the turning
operation was carbide. Carbide tools are more expensive when compared to high speed steel (HSS), but last longer
and can be much faster thereby proving more economical in the long run. Ajax lathe with maximum speed of 700
rpm was used for the turning operation and TM-8810 Coupling Ultrasonic Thickness Meter was used to test the
surface roughness of the specimen.

Method
The experimental procedure was carried out in the following steps: The material specimens (DMS) were cut into
required dimensions. The metal rod was mounted on the lathe chuck and secured appropriately and finally turning
operation was then carried out with a tungsten carbide tip tool for the required number of runs. The turning process
was done in the following three cases; keeping depth of cut and feed rate constant while spindle speed was varied;
keeping spindle speed and depth of cut constant while feed rate was varied, and keeping feed rate and spindle speed
constant while depth of cut was varied, Table 2 to Table 10 shows the setting parameters and the variations of the
three parameters to be investigated.

Table 2: Constant Spindle speed and Feed rate with varied Depth of cut
S/N Spindle speed Feed rate Depth of cut
(rpm) (mm/min) (mm)
1 400 0.20 0.75
2 400 0.20 0.50
3 400 0.20 0.25

Table 3: Constant Spindle speed and Depth of cut with varied Feed rate
S/N Spindle Speed Feed rate Depth of Cut
(rpm) (mm/min) mm
1 400 0.20 0.75
2 400 0.22 0.75
3 400 0.24 0.75
 Table 4: Constant Feed rate and Depth of cut with varied Spindle speed
S/N Spindle Speed Feed rate Depth Of Cut
(rpm) mm/min mm
1 400 0.2 0.75
2 450 0.2 0.75
3 700 0.2 0.75

Table 5: Constant Spindle speed and Feed rate with varied Depth of cut
S/N Spindle Speed Feed rate Depth of Cut
(rpm) mm/min mm
1 450 0.20 0.75
2 450 0.20 0.50
3 450 0.20 0.25

Table 6: Constant Spindle speed and Depth of cut with varied Feed rate
S/N Spindle Speed Feed rate Depth of Cut
(rpm) (mm/min) (mm)
1 450 0.20 0.75
2 450 0.22 0.75
3 450 0.24 0.75

Table 7: Constant Feed rate and Depth of cut with varied Spindle speed
S/N Spindle Speed Feed rate Depth of Cut
(rpm) mm/min (mm)
1 400 0.20 0.50
2 450 0.20 0.50
3 700 0.20 0.50

Table 8: Constant Spindle speed and Feed rate with varied Depth of cut
S/N Spindle Speed Feed rate Depth of Cut
(rpm) (mm/min) (mm)
1 700 0.20 0.75
2 700 0.20 0.50
3 700 0.20 0.25

Table 9: Constant Spindle speed and Depth of cut with varied Feed rate
S/N Spindle Speed Feed rate Depth of Cut
(rpm) (mm/min) (mm)
1 700 0.20 0.75
2 700 0.22 0.75
3 700 0.24 0.75

Table 10: Constant Feed rate and Depth of cut with varied Spindle speed
S/N Spindle Speed Feed rate Depth of Cut
(rpm) (mm/min) (mm)
1 400 0.22 0.50
2 450 0.22 0.50
3 700 0.22 0.50

Cutting process was performed to the desired length and diameter and set in the Ajax lathe with variation of spindle
speed, feed rate and depth of cut see Plate 1. The measurement of roughness values for the various variations of the
three parameters of the test specimens was carried (see Plate 2 and Plate 3) using TM-8810 COUPLING
ULTRASONIC THICKNESS METER resulting from the lathe process and recorded.
 Plate1: Workpiece on lathe during turning operation Plate 2: Surface tester on the surface of the
workpiece

Plate 3: Measuring and reading roughness value

V. EXPERIMENTAL RESULTS

The following Figures presents the experimental results obtained for dead mild steel. Fig. 1 shows a graph of
constant spindle speed of 400 rpm and feed rate of 0.2 mm/min it is observe that the value of Ra increases from
1.3µm to 2.0µm as the depth of cut reduces, also at constant spindle speed of 400 rpm and depth of cut of 0.75mm
with varied feed rate, the Ra value increases to 2.0µm as shown in Fig. 2.

2.5
Roughness Value (µm)

2
1.5
1
0.5
0
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Depth of cut (mm)

Fig. 1: Relationship of surface roughness with depth of cut

 2.5

Roughness value (µm)

2
1.5
1
0.5
0
0.2 0.2 0.21 0.21 0.22 0.22 0.23 0.23 0.24 0.24 0.25
Feed rate (mm/min)

Fig. 2: Relationship of surface roughness with feed rate

Fig. 3 further shows that roughness value reduces from 1.3µm to 1.1µm as the spindle speed increases when the
depths of cut and feed rate are held constant. Also it is observed in Fig. 4 that at constant spindle speed of 450rpm
and feed rate 0.20mm/min with varied depth of cut was a fluctuation in the Ra value from 2.8µm to 1.8µm and
2.4µm as the depth of cut increases.
1.35
1.3
Roughness value (µm)

1.25
1.2
1.15
1.1
1.05
1
350 400 450 500 550 600 650 700 750
Spindle speed (rpm)

Fig. 3: Relationship of surface roughness with spindle speed

3
Roughness value (µm)

2.5
2
1.5
1
0.5
0
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Depth of cut (mm)

Fig. 4: Relationship of surface roughness with depth of cut

Fig. 5 is a plot of roughness value against feed rate. It is observed that as the feed rate increases from 0.2mm/min to
0.24mm/min there is a linear increase in the Ra value from 1.1µm to 2.0µm when the spindle speed and depth of cut
are held constant. Again when the depths of cut and feed rate are held constant, with a varied spindle speed, it is
seen that there is a drop of in the Ra value from 1.5 µm to 1.2 µm as shown in Fig. 6.
 2.5

Roughness value (µm)

2
1.5
1
0.5
0
0.2 0.2 0.21 0.21 0.22 0.22 0.23 0.23 0.24 0.24 0.25
Feedrate (mm/min)

Fig. 5: Relationship of surface roughness with feed rate

1.6
1.4
Roughness value (µm)

1.2
1
0.8
0.6
0.4
0.2
0
350 400 450 500 550 600 650 700 750
Spindle speed (rpm)

Fig. 6: Relationship of surface roughness with spindle speed

For a spindle speed of 700rpm held constant with feed rate of 0.20mm/min, Fig. 7 shows the effect of varied depth
of cut in the machining parameters to roughness; that as the depth increases there is a corresponding increase in the
Ra value. This is seen to rise from 1.1µm to 1.8µm. Furthermore when the speed remains at 700rpm and depth of cut
held constant at 0.75mm and the feed rate varied it was observed that as it increases there is a drop in the Ra value
and then rises again, this can be seen in the plot in Fig. 8.

2
Roughness value (µm)

1.5

0.5

0
0.2 0.3 0.4 0.5 0.6 0.7 0.8
Depth of Cut (mm)

Fig. 7: Relationship of surface roughness with depth of cut

 2.5

Roughness value (µm)

2

1.5

0.5

0
0.2 0.2 0.21 0.21 0.22 0.22 0.23 0.23 0.24 0.24 0.25
Feedrate (mm/min)

Fig. 8: Relationship of surface roughness with feed rate

Fig. 9 shows the relationship of spindle speed with roughness when depth of cut and feed rate are held at constant
values. The plot shows a decrease in the surface roughness as the spindle speed increases.
1.8
1.6
Roughness value (µm)

1.4
1.2
1
0.8
0.6
0.4
0.2
0
350 400 450 500 550 600 650 700 750
Spindle Speed (rpm)

Fig. 9: Relationship of surface roughness with spindle speed

In Fig. 1, Fig.4 and Fig.7, the plot train shows the influence of the variation of depth of cut on the surface roughness
of dead mild steel. Fig. 2, Fig. 5 and Fig. 8 shows the influence of the variation of feed rate on dead mild steel.
Furthermore, Fig. 3, Fig. 6 and Fig.9 show the influence of the variation of spindle speed on dead mild steel. It is
observed from the graphs that an increase in feed rate increases the roughness value, a higher spindle speed on the
other hand with a minimum depth of cut results to a minimum roughness value.

VI. CONCLUSION AND FUTURE WORK

An experimental study on the effect of cutting variables on surface finish of mild steel has been carried out. The
experiment was done by varying and combination of three cutting parameters which are; spindle speed, feed rate,
and depth of cut. A conclusion was drawn that the minimum surface roughness in dead mild steel is obtained when
there is a combination of maximum spindle speed (700rpm) with a minimum depth of cut of 0.20mm, while a
minimum surface finish is obtained when the feed rate is high (0.75mm/min).

REFERENCES

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Guwahati, Assan, Indian Pages 459-1 to 459 -6
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[10] www.matweb.com/searcg/datasheet.aspx accessed 2020