While machining which of the following improves surface finish?

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BPSC AE Paper VI Mechanical 2024 Official Paper
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  1. Increased feed rate
  2. Increased cutting speed
  3. Formation of built up edge
  4. Increased depth of cut

Answer (Detailed Solution Below)

Option 2 : Increased cutting speed
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Detailed Solution

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Explanation:

Surface Finish:

  • Surface finish refers to the texture and smoothness of a machined surface, which is influenced by the machining parameters and the material properties. Achieving a good surface finish is critical in manufacturing, as it impacts the functional performance, aesthetic appeal, and fatigue strength of the component.
  • During machining, the interaction between the cutting tool and the workpiece material results in the removal of material in the form of chips. The surface finish is influenced by several factors, such as cutting speed, feed rate, depth of cut, tool geometry, and the formation of built-up edge (BUE). By optimizing these factors, manufacturers can achieve the desired surface quality.

Why Increased Cutting Speed Improves Surface Finish:

  • At higher cutting speeds, the cutting tool interacts with the workpiece material at a faster rate, leading to reduced friction and heat generation at the cutting zone.
  • Higher cutting speeds reduce the tendency for the formation of a built-up edge (BUE) on the cutting tool. The BUE is a common phenomenon in machining, where a layer of workpiece material adheres to the cutting edge of the tool. This adversely affects surface finish by creating irregularities and roughness on the machined surface.
  • When the cutting speed is increased, the material removal process becomes smoother and more uniform, resulting in a finer and more consistent surface texture.
  • Increased cutting speed enhances the shearing action and reduces the tearing effect on the material, thereby improving the quality of the machined surface.
  • For most materials, there exists an optimal range of cutting speeds that minimizes tool wear while achieving the best surface finish. Operating within this range ensures efficient machining and superior surface quality.

Limitations of Excessive Cutting Speed:

  • Excessive cutting speed can lead to increased tool wear and reduced tool life.
  • It may cause excessive heat generation, which can affect the metallurgical properties of the machined surface and lead to thermal damage.
  • High cutting speeds require advanced cutting tools and machine tools capable of operating at such speeds, which may increase operational costs.

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