Performance Evaluation of Feed Rate on Turning Mild Steel Using the Two-Way Application of Cutting Fluids

Abstract

The research was conducted to establish the influence of the feed rate on lathe machining (turning) using the two-way application of cutting fluids. The objective was to find out how the variation of the feed rate affect the surface quality of the machined surface, the tool wear (tool life) as well as the cutting zone temperature. The experimental research was conducted on a universal XL lathe machine under the following conditions: the material for the workpiece was low carbon steel (Mild Steel); the tool material was carbide insert; depth of cut was 1.5 mm; speed (spindle speed) was 125 rpm; the two-way application of cutting fluid was done at angle 30^o to each other; the feed rate range was from 0.75 to 1.75 mm/rev with the application of cutting fluid. The machining duration was 120 minutes. The factors evaluated were the tool wear, surface roughness and the temperature at the cutting zone. It was established that the higher the value of the feed rate the higher the rate of tool wear and the surface roughness, viz-a-viz the shorter the tool life and lower the machined surface quality. The increase in the temperature at cutting zone was not significant. When the feed rate was varied from 0.75 mm/rev to 1.75 mm/rev, the corresponding increase in values for surface roughness, tool wear and temperature at the cutting zone were 9.63 µm – 15.0 µm, 0.03 mm – 0.33 mm and 25.36^oC – 31.30^oC respectively. However, the greatest influence of the feed rate was on the tool wear (tool life). The increase in the rate of tool wear was 100%, whereas the other two parameters were less.