Sulaimani Polytechnic University

Technical College of Engineering

Department of Mechanic and Manufacturing
Engineering

Surface Roughness of Turning Products

Prepared: Muhammad Ali

Supervisor: Mrs. Shayma Ali

3rd Stage
Traditional and Nontraditional Machining
5th Semester

2023-2024
 Experiment No. 3

Experiment Name: Surface Roughness of Turning Products

Objective:
The primary objective of this study is to investigate and optimize the
surface roughness of turning products through a comprehensive
analysis of machining parameters. This research aims to:
1. Characterize Surface Roughness: Conduct a thorough examination of the
surface roughness profiles of turning products under varying machining conditions.

2. Identify Influencing Factors: Identify and analyze the key machining parameters
such as cutting speed, feed rate, and depth of cut that significantly affect the surface
roughness of turned components.

3. Optimization of Machining Parameters: Determine the optimal combination of

machining parameters to achieve the desired surface finish, balancing the trade-offs
between material removal rates and surface quality.
Equipment:

1. Lathe machine

2. Surface roughness measuring instrument

3. double tools with specified approach (𝜑 ≥ 𝜑1 )angles and

different nose radius equals (𝑟 = 0) and (𝑟 > 0)

4. Mild steel shaft.

Theory:

Explain surface roughness: The imperfections and departures from a

perfect, smooth surface present on a material's exterior are referred
to as surface roughness. Small-scale surface height changes are
usually its defining feature. The average roughness (Ra), average
maximum peak-to-valley height (Rz), and other characteristics are
used to quantify and measure surface roughness. In manufacturing
and engineering, surface roughness evaluation is critical because it
affects aspects of a product's operation, appearance, wear
resistance, friction, and overall quality.

Tool wear and feeding marks produce roughness because of their

short wave length. In addition to the workpiece bending as a result of
cutting forces, stresses, and strains, waviness is produced by the
relative vibration between the tool and the workpiece.
Define the benefit of surface finish in the machine parts:

1. Better Aesthetics: Machine parts have a polished and

expert appearance because of the visual appeal of their well-
finished, smooth surfaces.

2. Decreased Wear and Friction:

Smooth surfaces extend the life and efficiency of machines by
reducing wear and friction between moving parts.

3. Improved Functionality: Superior surface-finished parts

frequently have better functionality, which lessens the
possibility of problems like jams or unpredictable
movements.

4-Better Lubrication Retention: Having smooth surfaces

makes it easier for lubricants to adhere correctly and lessen
wear and friction.

5. Better Corrosion Resistance: A well-polished surface can

offer increased corrosion resistance, shielding the machine
parts from outside influences.

6-Tight Tolerance Control: Exquisite surface treatments help

machined items have tighter tolerances, which guarantees
accuracy and precision in their fit and dimensions.
Procedure:

1. Material Selection:
Choose the appropriate material for the turning process, considering
its machinability and the desired surface finish.
2. Tool Selection:
Select cutting tools suitable for the material and the desired surface
finish.
Consider factors such as tool geometry, coating, and cutting speed.
3. Cutting Parameters:
Adjust the cutting parameters based on the material and tool
characteristics.
Cutting Speed (V): Higher speeds often result in a smoother surface.
Feed Rate (f): Optimize the feed rate for material removal without
causing excessive tool wear.
Depth of Cut (d): Adjust the depth of cut based on the material and
machine capability.
4. Machine Setup:
Ensure the lathe or turning machine is properly calibrated and in
good condition.
Secure the workpiece firmly to minimize vibrations.
5. Coolant and Lubrication:
Use coolant or lubrication to dissipate heat and reduce friction during
the cutting process.
Proper lubrication can enhance tool life and improve surface finish.
6. Tool Wear Monitoring:
Regularly monitor tool wear to replace or re-sharpen cutting tools as
needed.
Worn-out tools can negatively impact surface finish.
7. Optimization:
Iteratively adjust cutting parameters based on initial results to
optimize the process for achieving the desired surface roughness.
8. Tool Path Strategies:
Consider the tool path strategy, such as the use of finishing passes or
optimizing the toolpath for a smoother finish.
Results:



Feed Depth of Cutting speed

(m/min)
Roughness (R)
(mm/rev) cut
(mm) (calculated) (measured)

0.07 0.5 300 0.04 0.5

0.15 0.5 300 0.086 0.65

0.23 0.5 300 0.132 1.3

0.3 0.5 300 0.173 2.08

Table 2:
Feed Depth of Cutting speed
(m/min)
Roughness (R)
(mm/rev) cut
(mm) (calculated) (measured)

0.07 0.5 300 0.000175 0.47

0.15 0.5 300 0.000803 0.51

0.23 0.5 300 0.00188 0.60

0.3 0.5 300 0.00321 0.68
Calculations:

if R=0

Table: 1
1-R=0.07*0.577=0.04
2-R=0.15*0.577=0.086
3-R=0.23*0.577=0.132
4-R=0.3*0.577=0.173

Table: 2

if R=0

1- R=0.00175
2- R=0.000803
3- R=0.00188
4- R=0.00321
Discussion:

Surface roughness in turning products is a crucial aspect that

significantly influences the overall quality and functionality of the
final products. Achieving the desired surface finish involves a
combination of careful tool selection, appropriate cutting
parameters, and precise machine setup.
The choice of material for turning plays a vital role in the overall
process. Different materials have varying machinability
characteristics, and selecting the right one is essential for achieving
the desired surface finish.
Tool selection is another critical factor. The cutting tools chosen must
be suitable for the material being turned and should have the
appropriate geometry and coating. These factors, along with cutting
speed, feed rate, and depth of cut, contribute to achieving the
desired surface roughness.
Proper machine setup is essential to ensure the turning process
operates smoothly. The lathe or turning machine must be calibrated
accurately, and the workpiece should be securely held in place to
minimize vibrations during the turning operation.
Coolant and lubrication are often used to dissipate heat and reduce
friction during the cutting process. This not only enhances the tool's
life but also contributes to achieving a smoother surface finish.