Determining the effect of processing parameters on the surface roughness and dimensional deviation of copper in dry turning operation

In copper dry turning, feed rate is the most important factor influencing the surface roughness, whereas cutting speed and cutting depth are insignificant factors. On the other hand, cutting depth and cutting speed have the greatest effect on the dimensional accuracy respectively, while nose radius has no significant effect. In order to achieve an acceptable surface roughness with suitable material removal rate and machining time, the combination of the lowest feed rate and the highest speed along with the moderate cutting depth and nose radius is suggested. The best surface roughness of 0.381 µm has been achieved at rε=1.2 mm, V=220 m/min, d=0.5 mm and f=0.08 mm/rev, which is comparable with the surface finish obtained by the conventional grinding. According to the results, the lowest level of cutting depth, moderate level of feed rate, and the speed lower than 1100 rpm, provide the best dimensional accuracy.