Determining the effect of processing parameters on the surface roughness and dimensional deviation of copper in dry turning operation

In copper dry turning, feed rate is the most important factorinfluencing the surface roughness, whereas cutting speed andcutting depth are insignificant factors. On the other hand,cutting depth and cutting speed have the greatest effect on thedimensional accuracy respectively, while nose radius has nosignificant effect. In order to achieve an acceptable surfaceroughness with suitable material removal rate and machiningtime, the combination of the lowest feed rate and the highestspeed along with the moderate cutting depth and nose radiusis suggested. The best surface roughness of 0.381 μm hasbeen achieved at rε=1.2 mm, V=220 m/min, d=0.5 mm andf=0.08 mm/rev, which is comparable with the surface finishobtained by the conventional grinding. According to theresults, the lowest level of cutting depth, moderate level offeed rate, and the speed lower than 1100 rpm, provide the bestdimensional accuracy.

Keywords:

Dimensional deviation , Surface roughness , copper , dry finish turning