Sources of surface roughness in metal cutting: Which factors commonly contribute to roughness on a machined surface?

Introduction / Context:
Surface roughness after machining arises from a combination of geometric, material, and dynamic effects. Understanding these contributors is essential for selecting parameters and tooling to meet finish specifications without excessive cost.

Given Data / Assumptions:

• Conventional turning/milling with single-point or multi-point tools.
• Stable machine setup but typical shop conditions.
• Tool geometry and speed/feed/depth of cut are adjustable.

Concept / Approach:
Tool feed leaves a theoretical scallop height (feed marks). Built-up edge (BUE) forms at low-to-moderate speeds and can intermittently break off, leaving surface tears. Machine/tool vibration (chatter) superimposes a waviness pattern that elevates roughness. All three mechanisms can operate simultaneously.

Step-by-Step Solution:

Verification / Alternative check:
Surface metrology often reveals distinct signatures (periodic feed marks, chatter wavelength). Corrective actions confirm the contributing mechanisms.

Why Other Options Are Wrong:
Limiting the cause to only one factor ignores the multifactorial nature of machining finish. Therefore, the comprehensive choice is best.

Common Pitfalls:
Chasing finish by coolant alone while ignoring feed or rigidity; using excessive nose radius that induces chatter; neglecting tool wear.

Final Answer:
all of these