Effect of Feed Rate on Surface Integrity and Tool Wear during Short Turning of AISI 1045 Carbon Steel

AISI 1045 medium carbon steel considered among materials that commonly used as machining product. The quality of machined surface of AISI 1045 strongly dependent on the characteristics of cutting tool and the cutting parameters. Inappropriate use of cutting parameters would lead to the accelerating tool wear and rough surface finish, which would lead to the deteriorate machining performance. This project presents of feed rate on the tool wear and surface roughness when turning AISI 1045 carbon steel without cutting fluid. This experiment was conducted at a short machining time using a CNC turning in dry condition with feed rates ranged from 0.15 mm/rev to 0.5 mm/rev, cutting speeds ranged from 35 m/min to 53 m/min and depth of cut constant at 1 mm. The results show that at the low feed rate of 0.15 mm/rev, the surface roughness demonstrated uneven trend ranged from 3.8 μm to 5.86 μm with the tool wear recorded increased from 0.0696 mm to 0.1405 mm. As the feed rate increased to 0.5 mm/rev, the surface roughness increased from 8.68 μm to 17.28 μm and the tool wear recorded increment from 0.0755 mm to 0.1810 mm. Surface finish appeared with feed marks and material side flow while the tool wear suffered with flank wear, crater wear and chipping. This study will provide guidelines to machine AISI 1045 effectively and provide understanding the characteristics of surface finish and tool wear especially under dry condition at a short machining time.