Analyzing the Effect of Feed Rate and Cutting Speed on Milling

This report investigates the influence of feed rate and cutting speed on surface roughness during milling processes. The study reflects on how reducing cutting speed increases surface roughness due to the built-up edge effect, while high feed rates enhance dynamic stability and surface roughness. Experimental results demonstrate that a small feed rate and high cutting speeds yield the best surface roughness quality during cold forging machining. The report emphasizes that high feed rates increase surface roughness, which improves specimen quality and reduces manufacturing costs by enhancing strength, creep resistance, and corrosion resistance. The findings highlight the importance of optimizing feed rate and cutting speed to achieve desired surface roughness characteristics in milled specimens, contributing to improved material properties and cost-effective manufacturing processes. Desklib provides access to similar reports and AI-powered study tools for students.

Running head; SURFACE ROUGHNESS IN MILLING
The Effect of Feed Rate and Cutting Speed on Surface Roughness in Milling
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Institution

SURFACE ROUGHNESS IN MILLING 2
The Effect of Feed Rate and Cutting Speed on Surface Roughness in Milling
The Effect of Feed Rate and Cutting Speed on Surface Roughness in Milling
Name
Institution

SURFACE ROUGHNESS IN MILLING 3
The Effect of Feed Rate and Cutting Speed on Surface Roughness in Milling
Reflection 1
This exercise made it clear to me that reducing the cutting speed of the machine tends to increase
the surface roughness due to the impact of built up edge on the surface of the specimen. This is
because the low cutting speeds prevent the occurrence of the built up edge during the milling
process which generates a large burr quantity on the machined surface. The impact of this is
improving the surface roughness and thus the quality of the surface finish of the specimen being
milled. The machine used to mill the specimen through increasing the cutting speed thus leads to
the advantages of surface roughness such as reduced loss of material, high tensile strength,
precision and high production rates. The cutting speed ought to be low in order to create groves
on the surface of the material, which contribute to surface roughness required for the different
advantageous benefits of machining in enhancing the corrosion resistance, strength and
resistance to creep (Özel, Hsu, & Zeren, 2005).
Reflection 2
Further I became aware that ensuring that the feeding rate remains high guarantees that the
cutting forces and the residual stresses from milling processes increases the dynamic stability of
the surface being milled thus increasing the surface roughness of the specimen. (Benardos &
Vosniakos, 2003). The feed rate refers to the speed at which the tool of milling machine
advances along its own cutting path to interact with the specimen being milled (Asiltürk &
Akkuş, 2011). Milling allows the specimen to have a more applicable desired shape contributing
to a good quality of surface finishing due to the high feed rate thus a reduction in the costs of
metal parts manufacturing in terms of the sizing tolerances that may be required for high

SURFACE ROUGHNESS IN MILLING 4
precision machining. This high feed rate also improves the benefits of a high surface roughness
through the reduction of machining time and costs as well as guaranteeing the fatigue strength
corrosion resistance and creep life of the part is guaranteed. (Korkut & Donertas, 2007) Thus the
feed rate affects the surface roughness in that it controls the amount of material being taken off
of the specimen being machined. As such the feed rate ought to be kept at a high rate in order to
allow the tool to have ample time with the surface of the specimen in order to produce a good
quality surface roughness
Discussion
The study was able to establish that having a small feed rate and a high cutting speeds produces
the best quality of surface roughness during cold forging machining. This is demonstrated in the
results through comparing the surface roughness of the aluminum specimen to the milling tool’s
cutting speed at a high and a low feeding rate. Results demonstrated that when the feed rate is at
180mm/min, the surface roughness increased at a negligible rate but began to decrease at high
cutting speeds. The highest roughness of 0.27 is noted at the lowest cutting speed. This is the
opposite in the case of the higher feed rate of 771mm/min where a higher cutting speed is seen to
cause a low surface roughness and the highest roughness coefficient achieved was 0.83. This
therefore implies that the surface roughness decreased as the cutting speed increases as has been
demonstrated in the findings of both the graphs. The impact of feed rate is also noted to have an
impact on the surface roughness of the specimen, because the values of highest roughness was
lower in the test run with a lower feed rate than the test run with the higher feed rate. This
therefore emphasizes that a high feed rate implies an increase in the surface roughness important
for the quality of the specimens and the costs of manufacturing in terms of reduction of time and

SURFACE ROUGHNESS IN MILLING 5
costs of operations. The quality of the specimen is enhanced in strength, creep, and resistance to
corrosion (Korkut & Donertas, 2007).
50 100 150 200 250 300 350 400 450 500 550
0
0.03
0.06
0.09
0.12
0.15
0.18
0.21
0.24
0.27
0.3
speed versus roughness using feed rate 180mm/min
speed
roughness

SURFACE ROUGHNESS IN MILLING 6
50 100 150 200 250 300 350 400 450 500 550
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
roughness versus speed using feed rate 771mm/min
speed
roughness
References
Asiltürk, I., & Akkuş, H. (2011). Determining the effect of cutting parameters on surface
roughness in hard turning using the Taguchi method. Measurement, 44(9), 1697-1704.
Benardos, P. G., & Vosniakos, G. C. (2003). Predicting surface roughness in machining: a
review. International journal of machine tools and manufacture, 43(8), 833-844.
Korkut, I., & Donertas, M. A. (2007). The influence of feed rate and cutting speed on the cutting
forces, surface roughness and tool–chip contact length during face milling. Materials &
design, 28(1), 308-312.
Özel, T., Hsu, T. K., & Zeren, E. (2005). Effects of cutting edge geometry, workpiece hardness,
feed rate and cutting speed on surface roughness and forces in finish turning of hardened

SURFACE ROUGHNESS IN MILLING 7
AISI H13 steel. The International Journal of Advanced Manufacturing Technology, 25(3-
4), 262-269.