EFFECT OF THE TURNING INSERT SHAPE AND FEED ON THE SURFACE PROFILE
DOI:
https://doi.org/10.20998/2078-7405.2026.104.07Keywords:
surface profile, turning, insert shape, feed, surface roughness, main effect plotAbstract
This study investigates the combined effect of cutting insert geometry and feed rate on surface roughness in turning of 42CrMo4 alloy steel. Controlled experiments were conducted on a CNC lathe using three insert geometries (C, D, and V types) and three feed rates (0.15, 0.25, and 0.35 mm/rev), while maintaining constant cutting speed and depth of cut. Surface characteristics were evaluated through quantitative roughness measurements and qualitative microscopic analysis. The results demonstrate that feed rate is the dominant factor influencing surface roughness, with increasing feed leading to a significant deterioration in surface quality, as reflected by higher Rz and Rt values. Insert geometry also plays a critical role: C and D inserts produce consistently lower roughness values, whereas the V insert results in inferior surface quality under identical cutting conditions. Notably, despite identical nose radii, substantial differences were observed between C and V inserts, highlighting the pronounced influence of edge geometry, particularly the end cutting edge angle. The findings indicate that conventional geometric models based solely on feed and nose radius are insufficient to accurately predict surface roughness. Instead, insert shape parameters must also be considered. This study contributes to improved understanding of the interaction between tool geometry and machining parameters and provides practical guidance for optimizing surface quality in turning operations.
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