Effects of Cutting Tool Parameters On Surface Roughness

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online) Volume 1, Number 1, July - Aug (2010), IAEME

182

EFFECTS OF CUTTING TOOL PARAMETERS ON
SURFACE ROUGHNESS
Tejinder pal singh
Department of mechanical engineering
SLIET, longowal

Jagtar singh
SLIET, longowal

Jatinder madan
SLIET, longowal

Gurmeet kaur
GNE, ludhiana
E-mail:- tejindergillz@gmail.com

ABSTRACT
This paper presents a study of the inuence of tool rake angle, nose radius and
clearance angle on surface roughness in turning operation using single point cutting
tool. The well-known material, Aluminium was used for the experimentation.
Mathematical models were developed from the data generated using full factorial
technique. Significance of the coefficients and adequacy of the developed models has
been checked using students t test and F test respectively at 95% confidence level.
Developed models have been found to be adequate. The influences of cutting
parameters have been presented in graphical form for better understanding. It was
found from the present study that surface roughness decreases with the increase in rake
angle and also increase with increase in the nose radius.
Keywords: Rake angle, Nose radius, Aluminium, Mathematical model, Surface
roughness.

International Journal of Mechanical Engineering
and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online) Volume 1,
Number 1, July - Aug (2010), pp. 182-189
IAEME, http://www.iaeme.com/ijmet.html
IJMET
I A E M E

183
1 INTRODUCTION
In order to produce any machine part at a certain quality by any metal removal
technique, cutting parameters should be arranged properly. Dependent upon work piece
material and geometry to be desired, surface roughness has important inuence on
determining the machining cost related to nose radius, rake angle, clearance angle,
cutting speed, feed rate, unformed chip thickness, cutting tool material etc. [1,6]. In metal
removal operations, many researches were carried out in the past and many are
continuing for the purpose of decreasing production cost without reducing product
quality. It was seen in all works on surface roughness by chip removal methods that the
surface roughness is directly inuenced by cutting parameters such as nose radius,
clearance angle, cutting speed, feed rate, depth of cut, tool rake angle. [2].Cutting tools
are insistently subject to pressure and opposing stresses during cutting even though their
cutting edges are sufficiently sharp while machining metallic and non-metallic materials.
Many researchers spent effort to determine optimum tool combination of rake angle and
nose radius for better surface finish. Problems during cutting process have been reduced
to an acceptable level by transferring computer knowledge for CNC turning machine.
There have been many studies concerning the effect of cutting parameters (nose radius
and rake angle) on the surface roughness. All results yielded from all these studies have
been evaluated. [3]
In this study, the inuence of tool rake angle nose radius on surface roughness
was determined during machining of Aluminium material, which has well known
physical, chemical and machinability properties. A computer numerical controlled (CNC)
machine is used for machining a rod of aluminium material in the present study. [4]
2 EXPERIMENTAL SET UP
The single point cutting tool trials were carried out using CNC Machine fitted
with specially designed tool. The metal rod taken for investigation was aluminium having
dimensions of 25mm diameter and length 80 mm was machined. The single point cutting
tools with rake angle (in degree), clearance angle (in degree) and nose radius (millimeter)
were used. The range of cutting tool parameters is shown in Table no. 1 [5]. The single

184
point cutting tool was mounted on the tool post of CNC machine. The main objective is
to optimize the parameters on turning operation for Surface roughness. [8]
The design of experiment is a procedure of selecting the number of trials and a
condition running them, essential and sufficient for solving a problem that has been set
with the required precision. The use of design of experiment makes the behavior of
investigator purposeful, organized and appreciably facilitates an increase in productivity
of his work and reliability of results obtained.
A two level factorial design of (2
3
= 8) eight trials, which is a standard statistical
tool to investigate the effects of number of parameters on the required response, was
selected for determining the effect of three independent direct tool parameters. The
commonly employed method of varying one parameter at a time, though popular, does
not give any information about interaction among parameters. The selecting of two level
factorial designs also helped in reducing experimental runs to the minimum possible.
The complete set of eight trials was repeated thrice for the sake of determining the
variance of optimization parameter and once for variance of adequacy for this model.
The experiments were performed in a random order in order to avoid any systematic
error. The responses for the three set of experiments are given in Table no. 2.This
experiments was performed in CAD/CAM lab. at SLIET, Longowal, Sangrur.
Table 1 Cutting Tool parameters and their limits
Parameters Units Symbol Upper
limit
Lower
limit
Rake angle Degree R 5 30
Nose radius Millimeter N .04 .08
Clearance angle Degree C 15 20
Table 2 Surface roughness of three sets
Experiment No. SR
1

1
st
Set

(m)
SR
2

2
nd
Set

(m)
SR
3

3
rd
Set

(m)
1. 1.780 1.834 1.708
2. 1.430 1.580 1.525
3. 0.769 0.827 0.860
4. 1.290 1.418 1.315
5. 1.180 1.080 1.250
6. 1.702 1.838 1.760
7. 0.615 0.745 0.620
8. 1.495 1.465
1.550

185
SR
1
= Surface Roughness of Set-I

SR
2
= Surface Roughness of Set-II
SR
3
= Surface Roughness of Set-III

3. DEVELOPMENT OF MATHEMATICAL MODEL
The response function representing surface roughness could be expressed as:
Y = f (R, N, C)
Assuming a linear relationship in the first instant and taking into account all
possible two factors interactions only, the above could be written as;
Y

= b
o
+b
1
R + b
2
N + b
3
C +b
12
RN + b
13
RC + b
23
NC ---------------------- (1)
Where b
0
is

combined effect of all parameters and b
1
, b
2
, b
3
are main effects and
b
12,
b
13
, b
23
are interactive effect of two parameters. The regression coefficients of the
selected model were calculated on basis of least square methods and shown in Table No.
3.
Table 3 Regression coefficients for Surface roughness
Coefficient Factor Value
b
0
Combined effects of all
factors
1.316
b
1
Rake angle (R) -0.212
b
2
Nose radius (N) 0.238
b
3
Clearance angle (C) 0.051
b
12
Interaction of R & N 0.127
b
13
Interaction of R & C 0.148
b
23
Interaction of N & C 0.053
3.1 Development of Final Models
The statistical significance of the coefficients can be tested by applying
studentst test. The level of significance of a particular parameter can be assessed by the
magnitude oft value associated with it. After dropping insignificant coefficients, the
developed models for surface roughness has been presented as Equation 2.
Y
SR
= 1.316 -0.212R + 0.238N + 0.127RN + 0.148RC ------------------ (2)
The adequacy of the developed models was tested using the analysis of variance
technique. According to this technique, the calculated value of the F-ratio of the model
developed should not exceed the standard tabulated value of F-ratio for a desired level
(95% in this case) of confidence. Adequacy results has been shown in Table No. 4


186
Table 4 Analysis of Adequacy Test
Degree of
Freedom
Variance of
Adequacy
Variance of
Response
FRatio
Model (F
m
)
F-Ratio
Table(F
t
)
Adequacy of
Model
F N S
2
ad
S
2
y
F
m
= S
2
ad
/ S
2
y
at 4, 8, 0.05
Whether
F
m
< F
t

4 8 0 .00475 0.00572 0.83 3.8 Yes
4 RESULTS AND DISCUSSION
The final proposed mathematical models for surface roughness as shown in
equation no. 2.Mathematical models can be used to predict the effects of the various tool
parameters on the surface roughness. In the mathematical model for the surface
roughness, the effects of interaction of three parameters can be explained well.
4.1 Influence of Rake Angle on Surface Roughness
The influence of rake angle on desired response has been observed from
mathematical model at presented in Fig.1. It is observed from the Fig.1 that with increase
in the rake angle, the surface roughness is decreases.

Figure 1 Effect of Rake Angle on Surface roughness
4.2 Influence of Nose Radius on Surface Roughness
From the mathematical model for surface roughness, the relationship between
surface roughness and nose radius is shown in Fig.2, it can be concluded that as the nose
radius increases, the surface roughness also increases. It is because by increasing the nose
radius, area of contact increases which in turn increases the friction and thus surface
roughness increases.

187

Figure 2 Effect of Nose Radius on Surface roughness
4.3 Interaction effect of Rake Angle and Nose Radius on Surface
Roughness
The effects of Rake Angle and Nose Radius on Surface Roughness were observed
from the Figure No.3. It can be concluded that by using lower value of nose radius and by
increasing the rake angle, surface roughness will be decreased and surface finish is
improved.

0.7
0.9
1.1
1.3
1.5
1.7
-1 1
Rake Angle in coded form
S
u
r
f
a
c
e

R
o
u
g
h
n
e
s
s

i
n

m
i
c
r
o
m
e
t
e
r
-N +N

Figure 3 Interactive effects of Rake Angle and Nose Radius on Surface roughness
4.4 Interaction effect of Rake Angle and Clearance Angle on Surface
Roughness
The effects of Rake Angle and Clearance Angle on Surface Roughness were
observed from the Figure. No.4. It is clear that surface roughness will be decreased i.e.
surface finish will be improved with decrease in value of clearance angle and increase in
value of rake angle.

188
0.9
1.1
1.3
1.5
1.7
-1 1
Rake Angle in coded form
S
u
r
f
a
c
e

R
o
u
g
h
n
e
s
s

i
n

m
i
c
r
o
m
e
t
e
r

-C +C

Figure 4 Interactive effects of Rake Angle and Clearance Angle on Surface roughness

CONCLUSIONS
Two Level Factorial Design is found to be effective tool to investigate the
interaction effects of parameters on the required response. Surface Roughness decreases
with increase in rake angle. The minimum value of surface roughness obtained is 1.104
m at rake angle of 30
0
and maximum value of surface roughness is 1.528 m at rake
angle of 5
0
.Surface Roughness increases with increase in nose radius. The minimum
value of surface roughness obtained is 1.078 m at nose radius of 0.04 mm and
maximum value of surface roughness is 1.554 m at nose radius of 0.08 mm.

Surface
roughness also decreases with the combined effect of rake angle & nose radius. The
minimum value of surface roughness obtained is 0.739 m at nose radius of 0.04 mm and
at rake angle of 30
0
and maximum value of surface roughness is 1.639 m at nose radius
of 0.08 mm and at rake angle of 5
0
and combined effect of rake angle & clearance angle.
The minimum value of surface roughness obtained is 0.956 m at clearance angle of 15
0

and at rake angle of 30
0
and maximum value of surface roughness is 1.676 m at
clearance angle of 15
0
and at rake angle of 5
0
.


189
REFERENCES
1. Korkut, M.A. Donertas, U. Seker, Three-dimensional dynamometer design and
production, Zku, Karabuk, Technical Education Faculty, J. Technol. 2 (12) (1999)
115129.
2. Hasan Gokkaya , Muammer Nalbant , The effects of cutting tool geometry and
processing parameters on the surface roughness of AISI 1030 steel, Materials and
Design 28 (2007) 717721.
3. Zimmer and Groover, CAD/CAM Computer-Aided Design & Manufacturing,
Pearson Education Ltd., 2006.
4. Degarmo, Materials and process of manufacturing, Printice Hall of India, 2003.
5. M.C. Shaw, Metal Cutting Principles, Oxford University Press, London, 1984.
6. J. Paulo Davim, A note on the determination of optimal cutting conditions for
surface finish obtained in turning using design of experiments, JMPT 116 (2001)
305-308.
7. Thomas M., Beauchamp Y., Youssef A. Y., Masounave, Effect of tool vibrations on
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on surface roughness Proceeding of the 2001 Industrial Engineering Research
Conference Copyright,2001, Institute of Industrial Engineers, paper no. 2036.

Effects of Cutting Tool Parameters On Surface Roughness

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),

ISSN 0976 6359(Online) Volume 1, Number 1, July - Aug (2010), IAEME

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