Effect of Machining Parameters on Surface Roughness during Milling of Steel

Muhammad Arham; Wasim Ahmad; Sajid Raza Zaidi; Salman Hussain; Mirza Jahanzaib

doi:10.58915/aset.v5i1.3201

Authors

Muhammad Arham University of Engineering and Technology (UET), Pakistan
Wasim Ahmad University of Engineering and Technology (UET), Pakistan
Sajid Raza Zaidi National University of Technology (NUTECH), Pakistan
Salman Hussain University of Engineering and Technology (UET), Pakistan
Mirza Jahanzaib University of Engineering and Technology (UET), Pakistan

DOI:

https://doi.org/10.58915/aset.v5i1.3201

Keywords:

Surface Roughness, ANOVA, Milling Machine

Abstract

Surface roughness has been the most extensively studied parameter in machining and remains a key indicator of process efficiency, surface quality, energy consumption, and productivity. With the growing emphasis on sustainable manufacturing, this study investigates the effect of a biodegradable lubricant (sunflower oil) on surface roughness during milling, as an alternative to conventional synthetic cutting fluids. An experimental analysis was conducted on SS 304, a widely used yet difficult-to-machine engineering material, using the Response Surface Methodology with a Central Composite Design. A total of 45 experiments were conducted by varying the depth of cut, feed per tooth, cutting speed, and cutting conditions (sunflower oil, conventional lubricant, and dry machining). The results were analyzed using ANOVA, which revealed depth of cut as the most significant factor influencing surface roughness with a contribution of 58.49%, followed by cutting speed (7.53%) and feed per tooth (5.89%), while cutting condition showed the least significance. Although the improvement in surface quality with sunflower oil was marginal compared to that with the conventional lubricant, it was notably superior to dry machining, demonstrating that sunflower oil can be effectively used as a sustainable lubricant without compromising surface quality.

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