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The Effect of Cutting Speed and Feed Rate on Surface Roughness and Tool
Wear when Machining Machining D2 Steel

Article  in  Materials Science Forum · November 2017

DOI: 10.4028/www.scientific.net/MSF.909.80

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Materials Science Forum Submitted: 2017-07-26
ISSN: 1662-9752, Vol. 909, pp 80-85 Accepted: 2017-07-27
doi:10.4028/www.scientific.net/MSF.909.80 Online: 2017-11-16
© 2017 Trans Tech Publications, Switzerland

The Effect of Cutting Speed and Feed Rate on Surface Roughness

and Tool Wear when Machining D2 Steel
Mohd Rasidi Ibrahim1,a, Tharmaraj Sreedharan1,b, N. ‘Aisyah Fadhlul Hadi1,c,
Mohammad Sukri Mustapa2,d, A. Emran Ismail2,e, Mohd Fahrul Hassan2,f,
and A. Mubarak Tajul Arifin2,g
1
Precision Machining Research Center (PREMACH), Faculty of Mechanical and Manufacturing
Engineering, Universiti Tun Hussein Onn Malaysia, Johor, Malaysia
2
Structural Integrity and Monitoring Research Group (SIMReG), Faculty of Mechanical
and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Johor, Malaysia
a
rasidi@uthm.edu.my, bcd130087@siswa.uthm.edu.my, cnurulaisyah.fadhlulhadi93@gmail.com,
d
sukri@uthm.edu.my, eemran@uthm.edu.my, ffahrul@uthm.edu.my, gmubarak@uthm.edu.my
Corresponding author: rasidi@uthm.edu.my

Keywords: Cutting Speed, Feed Rate, Surface Roughness, Tool Wear, D2 Steel

Abstract. Machining parameters is a main aspect in performing turning operations using lathe
machines. Cutting parameters such as cutting speed, feed rate and depth of cut gives big influence on
the dynamic behavior of the machining system. In machining parts, surface quality and tool wear
are the most crucial customer requirements. This is because the major indication of surface quality
on machined part is the surface roughness and the value of tool wear. Hence, to improve the surface
roughness and minimize the forming of tool wear, the optimum feed rate and cutting speed will be
determined. The input parameter such as cutting speed, feed rate and depth of cut always influence
the tool wear, surface roughness, cutting force, cutting temperature, tool life and dimensional
accuracy. The D2 steel was being investigated from the perspective of the effect of cutting speed
and feed rate on its surface roughness and tool wear. The results show that cutting speed is the main
parameter which affects the surface roughness where the most optimum parameter would be at
cutting speed of 173, 231 and 288 m/min with feed rate of 0.15 mm/rev. The tool wear strongly
affected by feed rate where at 0.15 mm/rev the tool wear value is the lowest. The combination of
high cutting speed and low feed rate was the best parameter to achieve smooth surface roughness.

Introduction
Surface texture in definition is the repetitive or random deviation from the nominal surface that
forms the three dimensional topography of the surface. Generally, surface texture consists of
roughness (nano and microroughness), waviness macroroughness), lay and flaws. A texture can
demonstrate roughness or waviness. The waviness may result due to the machine or work
deflections, vibrations, chatter and heat treatment. Waviness includes all irregularities which is the
spacing is greater that the roughness sampling length and less than waviness sampling length. Lay
can be referred as the principal direction of the predominant surface pattern which is determined by
the production method. Furthermore, flaws can be defined as unintentional, unexpected and
unwanted interruptions that are produced in the texture.
There are two components to be machined in surface finish. The first is the ideal or geometric
finish which is the finish that would result from the geometry and kinematics motions of the tool.
The ideal finish can be calculated from the feed rate per tooth, the tool nose radius and the tool lead
angle. The second component is the natural finish which results from tool wear, vibration, machine
tool errors and work material effects such as inhomogeneity build-up edge (BUE) formation and
rupture at low cutting speeds.
Surface roughness has become one of the main aspects in machining. It can be defined as a
surface texture of material or workpiece that is machined. Surface roughness analysis is critical to
control in many fields of research and industry. In machining process, surface roughness is

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 Materials Science Forum Vol. 909 81

always being selected as a main aspect in order to find the quality of the product. Every surface has
certain form of texture which is generated by the combination of different effects such as an action
of cutting tool on the material, microstructure of material and the instability in the cutting tool. Ciftci
[1] has found that cutting speed is affected surface roughness value when using austenitic stainless
steel (AISI 304 and AISI 316).
The mechanism of tool wear is extremely complicated and depends on the material of the tool,
workpiece to be machined, cutting variables (speed and chip cross-sectional area), type of coolant,
tool of geometry and the condition of the machine tool and its rigidity. Tool wear most commonly
measured by examining the wear scar on the tool using a microscope or stylus tracing instrument.
In machining process, the cutting tools used to remove material in order to create a required shape
and design of a workpiece. During that process, wear will be produced during the cutting action and
causes failure of cutting tool. The forming of tool wear is due to the increase of cutting temperature
and cutting force [2] Many kind of tools are used or developed such as lathe machine that include its
variety of machine types in order to produce good surface roughness for the product and increase
the quality of the product itself. During that process, wear will be produced during the cutting action
and causes failure of cutting tool.
Choudhury [3] stated that flank wear was caused by friction between the flank face of the tool and
the machined surface. When the tool wear reached a certain stage, it has to be re-sharpened or change
in order to get desire form and surface roughness of workpiece. Wear occurred when high speed
turning is applied in cutting speed due to high temperature generated in high speed machining.
The negative rake angle causing tool wear becomes high and it is because of the tool forces
usually raise as the tool is worn, the clearance angle is destroyed and the area of contact with the
clearance face is increased by flank wear. When the temperature rises, it affects the tool wear and
lead to excessive heat. High feed rate is the main parameter that causes of tool wear occurred.
Many researchers have conducted research and experiments by using different materials and process
related to tool wear. Davim [4] used D2 steel with ceramic tool, it can be seen that cutting velocity
affects tool wear to increase. In order to improve surface roughness and minimize the forming of
tool wear, the effect of cutting speed and feed rate on surface roughness and tool wear were
investigated.
Besides that, the suitable cutting speed and feed rate in order to improve surface roughness and
minimize the forming of tool wear were determined. Rasidi [5] found that after the process of
machining, the surface quality related very closely with the parameters of cutting and the geometries
of tool. The process of machining will fade the surface quality if the unsuitable parameters are used
such as dull tools, too high feed speeds or depth of cut, inadequate cutting speeds, coolant or
lubrication, or incorrect tool hardness.

Experimental Work
Surface Roughness. The cutting parameters of this study were being considered from the starting
of turning operations. The two main parameters values were kept as variable parameters that are the
cutting speed and feed rate. Meanwhile the depth of cut value was kept constant. The specifications
of Mitutoyo SJ-400 are shown in the Table 1 meanwhile Table 2 shows the machining parameters.
In this research, Mitutoyo SJ400 is used to measure the surface roughness of the workpiece after the
turning process.
Table 1: Specification of Mitutoyo SJ-400
Reference Specification
Measuring method Skidless / Skidded measurement
Measuring speed 0.05, 0.1, 0.5, 1.0 mm/s
Return speed 0.05, 0.1, 0.5, 1.0 mm/s
Assessed profile Primary profile, Roughness profile, Filtered waviness profile
Measuring range Up to 2400µ
Roughness standard JIS (JIS B0601-2001/1994/1982), DIN, ISO
82 5th Asia Conference on Mechanical and Materials Engineering

Table 2: Machining parameters

Cutting Parameter Values
Cutting speed, Vc (m/min) 173, 231, 288
Feed rate, fr (mm/rev) 0.15, 0.20, 0.25
Depth of cut, d (mm) 2
Machining condition Dry Cutting

(a) (b)
Figure 1: Mitutoyo SJ-400 and part of surface roughness (Ra) measurement
Data collection. In order to give more specific information about the type of D2 Steel used,
microhardness test had been applied to the workpiece through the microhardness test. Fig. 2 (a)
shows the Shidmadzu Microhardness Vikcers tester and Fig. 2 (b) shows an indention on top of D2
Steel surface. The result of microhardness test is shown in Table 3.
Table 3: Result of microhardness test
No H Length V Length Average Length Hardness (HV) Hardness (HRC)
1 45.9018 45.5295 45.7157 443.633 44.8
2 48.1265 47.8842 48.0054 402.505 41.5
3 46.3421 44.6573 46.4997 424.271 42.6
Mean 423.470 43.0

Figure 2: (a) Shidmadzu Microhardness Vikcers tester machine and (b) Indention on top of D2 Steel
surface
The experiment was performed by inserting the D2 steel into a Harrison Alpha 400 Lathe Machine
with variations of parameters and the turning insert is coated with carbide insert. Sandvik Coromant
type of turning tool holder was used for this study. The details are shown in Fig. 3. After the turning
process, the surface roughness of those steels were investigated by using Surface Roughness Tester
(Mitutoyo SJ-400).
Fig. 4 shows the sample of surface roughness result analysis that produced from the machine.
The data been measured by using the High Magnifying Measuring Microscope (OLYMPUS STM6).
After that, the sample of tool flank wear result that was obtained is as shown in Fig. 5. The surface
roughness of the machined workpiece was measured four times at four different positions in order
to get the average value of surface roughness. To measure the tool wear, after each cutting trial the
tool need to be measured and observed under the microscope.
 Materials Science Forum Vol. 909 83

Product Information Specification

Total cutting edge angle (KAPR) 93˚
Tool lead angle -3˚
Max. ramping angle (RMPX) 44˚
Max. overhang (OHX) 37.6 mm
Shank width (B) 25 mm
Shank height (H) 25 mm
Functional length (LF) 150 mm
Functional width (WF) 32 mm
Functional height (HF) 25 mm

Figure 3: Schematic drawing, information and specifications of turning tool holder

Figure 4: Surface roughness result analysis Figure 5: Tool wear result measurement
from Mitutoyo SJ-400 at tool tip

Result and Discussion

Result. A total of 27 samples collection were taken for surface roughness and 9 samples collection
for tool wear. The graphs in Fig. 6 for the effect of feed rate, fr (mm/rev) on surface roughness, Ra
(µm) for three different cutting speed were obtained. The surface roughness of the workpiece is
measured four times on four different areas to obtain the average value of surface roughness. As the
workpieces were examined by three different cutting speed, it shows that when the cutting speed
becomes higher, the value of surface roughness will decrease [6].

(a) (b)
Figure 6: The effect of feed rate, fr (mm/rev) on surface roughness, Ra (µm) for cutting
speed, Vc = 173 m/min and Vc = 288 m/min
84 5th Asia Conference on Mechanical and Materials Engineering

In Fig. 6 (a) the value of roughness at 0.15 mm/rev of feed rate resulted 1.94 µm at the first point,
then it increased to 2.15 µm at the second point before it flop to 2.01 µm at third point. Meanwhile in
Fig. 6 (b) at 0.15 mm/rev, the first, second, and third points show 4.95, 4.97 and 4.91 respectively.
From the result in Fig. 6, (a) and (b), the value of roughness is decreasing at each different feed rate
value that were investigated at different cutting speed.
Discussion. When the feed rate increase, the value of surface roughness will also increase [6]. This
can be seen in Fig. 7. From the results in Fig. 7, it can be understood that the cutting speed and feed
rate have its own effect on tool wear analysis. When the feed rate becomes higher, the value of tool
wear also will become higher [7]. Moreover, the tool wear value is increasing for each feed rate value
for each of the cutting speed.

(a) (b)
Figure 7: Comparison on results of tool flank wear after cutting speed and feed rate
For example, based on Fig. 7 (a), at feed rate of 0.15 mm/rev and cutting speed of 173 m/min the tool
wear value shows 51.1 µm. At the other hand, Fig. 7 (b) gives 73.4 µm of the tool flank wear which
is bigger than Fig. 7 (a) values. So it is proven that in terms of cutting speed is when the cutting
speed increase the value of tool wear will also increase [8]. From all parameters and results that
have been obtained, the lowest tool flank wear value can be seen at the cutting speed of 173 m/min
and feed rate of 0.15 mm/rev.

Acknowledgment
This work is supported by the Office for Research, Innovation, Commercialization and
Consultancy Management (ORICC) and Graduates Studies Centre of Universiti Tun Hussein Onn
Malaysia.

Conclusion
The cutting speed is the main parameter which affects the surface roughness. When the cutting
speed is higher, the surface roughness will be decrease. Meanwhile, the feed rate causes the value of
roughness to increase. The higher the feed rate, the surface roughness will become rougher.
Furthermore, the feed rate is the main parameter which affects the tool wear. It can be concluded
that, when the feed rate is high, the formation of tool wear is high. Besides that, the cutting speed
also causes the value of tool wear to increase. The higher the cutting speed, the higher the
formation of tool wear. Then, the combination of high cutting speed and low feed rate was the best
parameter to achieve smooth surface roughness. However, the combination of low cutting speed and
low feed rate was the best parameter to minimize the formation of tool wear.
 Materials Science Forum Vol. 909 85

Recommendation
From the research undergone, there are some recommendations for improvement of the project. The
experiment should be done using different type of insert with different coating, insert shape and
different angle of cutting. Moreover, the experiment should be done by using different range of
cutting parameters in order to get more accurate results. Lastly, the experiment can be done by
using different workpiece material.

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