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Effect of Depth of Cut, Cutting Speed and Feed Rate on Induced Vibration and
Surface Roughness in the Turning of 41Cr4 Alloy Steel

Article · January 2015

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 1, January 2014)

Effect of Depth of Cut, Cutting Speed and Work-piece

Overhang on Induced Vibration and Surface Roughness in the
Turning of 41Cr4 Alloy Steel
C.O. Izelu1, S.C. Eze2, B.U. Oreko3, B.A Edward4
1
Senior Lecturer, 4Lecturer, Department of Mechanical engineering, FUPRE, Effurun, Delta State, Nigeria
2
PG Student, Department of Mechanical Engineering, NDA, Kaduna, Kaduna State, Nigeria
3
Lecturer, Department of Welding engineering and offshore Technology, PTI, Effurun, Delta State, Nigeria
Abstract– The effect of turning parameters on induced Thus, the choice of optimized cutting parameters
vibration and work surface roughness of 41Cr4 alloy becomes very important to control the required surface
steel was experimentally examined. Response Surface quality. Chen and Smith [4] observed that metal cutting is
Methodology in conjunction with third order composite one of the most significant manufacturing processes in the
factorial Design is used to evaluate the effect of turning area of material removal. To optimize the system, several
parameters on induced vibration amplitude and surface researchers have developed mathematical models to predict
roughness. The results, from the turning operations the surface roughness in terms of various process
performed in the experiment, gave rise to a predictive parameters during turning of different materials.
second order response surface equation. Besides, it was For instance, Kopac and Bahor [5] examined the
observed that turning parameters (dept of cut, cutting changes in surface roughness of AISI 1060 and AISI 4140
speed and work piece overhang) had significant effect steels and analyzed the effect of cutting parameters by
on the surface roughness of work piece, and to a relative using RSM. Choudhury and El-Baradie [6] developed
degree, influenced induced vibration. It also shows that surface roughness prediction model in turning of high
the induced vibration and surface roughness of work- strength steel by factorial design of experiments. Nalbant et
piece is directly proportional to the depth of cut, cutting al [7] examined Taguchi method in the optimization of
speed and work piece overhang. cutting parameters for surface roughness in turning. Sahin
Y. Motorcu [8] used RSM to model the surface roughness
Keyword– Turning Parameter, Alloy Steel, induced of machined hardened AISI 1040 steel using triangular and
vibration, surface roughness square tools. Ozel and Karpat [9] used regression analysis
to predict Artificial Neural Network (ANN) for predictive
I. INTRODUCTION modeling of surface roughness and tool wear in turning.
Vibration is a frequent problem, which affects results of Mansour et al [10] studied a surface roughness model that
the machining, and in particular, surface finish in turning utilizes RSM for milling of steel in dry condition.
operation (Sayeed Ahmed G. M. [1]). Tool life is also Many new alloys have also been developed to react to
influenced by vibration. Severe acoustic noise in the today applications. As a result, there will always be a need
working environment frequently results as a dynamic for continuous research and improvements on tool and
motion between the cutting tool and the work piece. In all work-piece materials, cutting conditions and parameters to
cutting operations like turning, boring and milling optimize the output. Many researchers have studied the
vibrations are induced due to deformation of the work impact of these factors. However, work piece overhang as
piece. Several machining parameters, such as cutting speed, it affects the surface roughness, especially during the
feed rate, work piece material, and cutting tool geometry turning process, has not been adequately examined. The
have significant effects on the process quality. This implies purpose of this paper is to investigate experimentally the
several disadvantages, economical as well as environmental effects of turning variables (work piece overhang, dept of
(Thomas L. Lago [2]). cut and cutting speed as treatment factors) on induced
Keraita J. N. [3] reported that in machining operation, vibration and the resulting surface roughness (as response
the quality of surface finish is an important requirement for variables) in lathe turning of 41Cr4 alloy steel using
many turned work pieces. response surface Methodology (RSM).

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 1, January 2014)
II. EXPERIMENTATION AND METHOD OF ANALYSIS Chatter always gives rise to defects on the machined
surface; vibration especially self-excited vibration is
A. Materials and Equipment
associated with the machined surface roughness A
The following Materials and equipment are used to Vibration Meter 908Be series type measurement devise
perform the experiment; Work-piece type 41Cr4 alloy steel (Fig 4), was used for measuring the amplitude and velocity
round bar of 25Ø x 150 mm with the following of a point on the cutting tool. The tool vibration level was
specifications; (UTS = 902.83 N/mmm2, BHN = 278.55 measured using a vertical data of a transducer mounted
and chemical composition of 0.4%C, 0.25 S, 0.65 Mn, 1.0 near to the tip and connected to the devices. The data
Cr) (Fig 1); conventional lathe Machine (Fig 2) with include displacement and velocity of the indicated point on
carbide (F30 Type) cutting tool (Fig 3) of dimension the tool for each sample. The acceleration was calculated
(25x25x12.5mm) type (HSS-718) with the following by using general equation relating amplitude to
angles; back and side rake angle is 10o, 12o respectively, acceleration.
side relief angle is 5o and side cutting edge angle is 15o
using the stardard angle given in Jaton N.W[11].

Figure 4: Vibration Meter

Figure 1: Work-Piece Material

Figure 5: Set-Up for the Measurement of Induced

Figure 2: Lathe machine Vibration

C. Work Surface Roughness

An inside surface Roughness tester, ISR-16 type
instrument (Fig 6) was used for the measurement of surface
roughness. Three different positions for each sample at
120o with each other and the average of the three reading
are considered as surface texture of the turned surface.

Figure 3: Cutting Tool

B. Induced Machining Vibration

Self-excited vibration or self- induced vibration, which
is also known as chatter, is the basis under consideration. It
is caused by the interaction of the chip removal process and Figure 6: Surface Roughness Tester
the structure of the machine tool that results in disturbances
in the cutting zone.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 1, January 2014)
D. Response Surface Method The constant variables are given in Table III. The
A third order composite factorial design and Response dependent variables are the resulting surface finish and the
Surface Methodology RSM were chosen, so that different acceleration in both radial and feed directions. In order to
interactions between independent variables could be minimize the effect of tool wear, which could affect the
effectively investigated. The levels of the independent surface roughness, the tool was changed after 4 cuts. The
variables are as shown in Table I. The independent newly installed tool was run for a few machining times to
variables considered in the study are dept of cut F1, cutting eliminate rapid tool wear.
speed F2, and work-piece overhang F6 as shown in Table II.
Table I
Levels of Independent Variables

Levels
S/N Factor Design Design of Exp. Notation Symbol Unit Low Medium High
1 Depth of cut F1 T mm 1.0 2.0 3.0
2 Cutting speed F2 N rpm 260 320 400
3 Feed rate F3 F mm/rev 0.15 0.20 0.30
4 Tool nose radius F4 R mm 0 1 2
5 Tool overhang F5 ht mm 50 55 60
6 Work-piece overhang F6 hw mm 80 100 120

Table II AF1 , F2 , F6   0.172  0.079 F1  0.054 F2

Independent Parameters Under Consideration
Levels  0.002 F6  0.077 F12  0.023F22 (1)
S/N Parameters Unit Low Medium High
 0.020 F62  0.053F1 F2
1 Depth of cut mm 1.0 2.0 3.0
2 Cutting speed rpm 260 320 400  0.028F1 F6  0.031F2 F6
6 Work-piece mm 80 100 120
overhang Ra F1 , F2 , F6   8.104  0.558F1  0.669 F2
 0.093F6  1.827 F12  1.601F22 (2)
Table III
Constant Variables  1.629 F62  0.328F1 F2
Levels
S/N Parameters Unit low medium high
 0.046 F1 F6  0.288F2 F6
1. Tool mm 50 55 60
Overhang
2. Tool Nose mm 0 1 2
Radius
3. Feed Rate mm/rev 0.15 0.20 0.30

III. RESULT AND DISCUSSION

The study was undertaken to investigate the effect of
turning parameters (dept of cut, cutting speed and work
piece overhang) on induced vibration and surface
roughness by turning 41Cr4 alloy steel. Machining data for
dept of cut, cutting speed and work piece overhang on Figure 7: Machine Work-Pieces
induced vibration and surface roughness, were tabulated
accordingly in table IV. The result from the turning Response Surface Methodology is used in conjunction
operating performed in the experiment gave rise to a with third order composite factorial design to evaluate the
predictive RSM equation for induced vibration (A) and effect of turning variables ( dept of cut, cutting speed and
surface roughness (Ra) respectively, given as: work piece overhang) on induced vibration amplitude and
the surface roughness as in shown in Table IV below.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 1, January 2014)
The design of experiment took into consideration 27 From experimental results, turning variables (dept of cut,
experimental run consist of three (3) levels (low, medium, cutting speed and work piece overhang) has significant
high) (Table III) of the following independent variables; effect on the surface roughness of work piece and to a
depth of cut F1 (1.0, 2.0, 3.0 mm), cutting speed F2 (260, relative degree influences induced vibration. It also shows
320, 400 rpm) and work piece overhang F6(80, 100, 120 that the induced vibration and surface roughness of work-
mm), to produce different response surface roughness as piece is proportional to the depth of cut, cutting speed and
shown in Table IV. work piece overhang.

Table IV
Third Order Composite Factorial Design
Induced Vibration Surface Roughness
Experimental Factor
Amplitude
Run Acceleration Predicted Ra Value (mm) Predicted
F1 F2 F6
1 1.0 260 80 0.15 0.17 7.712 8.14
2 1.0 260 100 0.15 0.19 10.781 9.43
3 1.0 260 120 0.18 0.17 7.612 7.47
4 1.0 320 80 0.14 0.12 5.579 5.25
5 1.0 320 100 0.18 0.17 5.209 6.83
6 1.0 320 120 0.24 0.18 5.867 5.16
7 1.0 400 80 0.14 0.11 6.044 5.57
8 1.0 400 100 0.21 0.19 5.869 7.44
9 1.0 400 120 0.14 0.23 6.673 6.05
10 2.0 260 80 0.13 0.15 8.441 9.13
11 2.0 260 100 0.06 0.14 12.857 10.37
12 2.0 260 120 0.13 0.09 6.02 8.36
13 2.0 320 80 0.13 0.15 5.613 6.57
14 2.0 320 100 0.20 0.17 8.213 8.10
15 2.0 320 120 0.24 0.15 5.237 6.38
16 2.0 400 80 0.16 0.19 6.519 7.21
17 2.0 400 100 0.33 0.25 13.300 9.04
18 2.0 400 120 0.16 0.26 6.562 7.60
19 3.0 260 80 0.37 0.28 6.275 6.46
20 3.0 260 100 0.37 0.24 6.551 7.66
21 3.0 260 120 0.05 0.17 6.374 5.60
22 3.0 320 80 0.25 0.33 5.988 4.23
23 3.0 320 100 0.19 0.33 4.701 5.72
24 3.0 320 120 0.29 0.28 5.789 3.95
25 3.0 400 80 0.46 0.43 5.579 5.20
26 3.0 400 100 0.43 0.46 4.093 6.98
27 3.0 400 120 0.54 0.44 5.944 5.50
The average values of induced vibration and surface The actual amplitude of the induced vibration between
roughness (Ra) result were also plotted on a graph to give a tool and work-piece was measured using a displacement
better understanding of the results. The relationship sensor.
between depth of cut ( F1), Cutting speed (F2) and work-
piece overhang (F4) with acceleration amplitude and the
surface roughness of work piece for cutting condition is
plotted in Figs. 8 and 9 respectively.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 1, January 2014)
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