STUDY INTO THE EFFECT OF CUTTING SPEED ON THE SURFACE ROUGHNESS, ROUNDNESS, TOOL WEAR AND CHIP FORMATION DURING LATHE CUTTING OPERATION

Water soluble metal cutting fluids are used extensively in metal removal processes to
act as a cooling and lubricating agent. The application of the metal cutting fluid is
typically used according to the concentration recommended by the manufacturer. To
minimize the production cost, metal cutting fluid usually diluted with the minimum
recommended concentration given. The objective of this project is to recommend the
best cutting condition during lathe cutting operation using the minimum concentration
recommended. A commercial metal cutting fluid recommended that the minimum
concentration for turning operation is 8%. Therefore, this project is conducted by
turning AISI 304 Austenitic Stainless Steel workpiece with the application of 8%
concentration of metal cutting fluid. The machining parameter of turning operation
involved was cutting speed. A comparative study was conducted to study the effect of
variation of cutting speed to surface roughness, roundness, tool wear and chip
formation. Experiments started with turning sample of AISI 304 Austenitic Stainless
Steel workpiece by heavy duty lathe machine using the smallest cutting speed,
60m/min which was selected based on the standard that fit with the machine
capabilities. The analyzing development was conducted using Mitutoyo Surface
Proftler and Mitutoyo Round Test machine to measure surface roughness and
roundness respectively. 3D Non Contact Measurement was used to identify tool flank
wear occurred and types of chip produced with perfect image. The results obtained
were compared with three other experiment conditions, 90m/min, 180m/min,
200m/min. From this analysis, it is realized that performance of both cutting tool and
machining parts was highly influenced by cutting speed.