Analyzing the effects of machining parameters on surface roughness of machined surfaces using vision system

2021 ◽  
Author(s):  
D.M. Shivanna ◽  
M.B. Kiran ◽  
G.S. Venkatesh ◽  
S.D. Kavitha
Keyword(s):  
Surface Roughness ◽  
Vision System ◽  
Machining Parameters ◽  
Machined Surfaces

A Novel Approach to Quantifying Surface Roughness in Grinding

2007 ◽  
Vol 339 ◽  
pp. 147-151
Author(s):  
Chun Hua Ju ◽  
Yi Xie
Keyword(s):  
Surface Roughness ◽  
Standard Deviation ◽  
Vision System ◽  
Computer Control ◽  
Mean Value ◽  
Quality Characteristic ◽  
Edge Image ◽  
Gray Image ◽  
Novel Approach ◽  
Machined Surfaces

Surface roughness is an important quality characteristic in grinding. Measurement of surface roughness by means of mechanical stylus is widely done in metrology. In this paper, a new machine vision system has been utilized to quantify the surface roughness of machined surfaces (ground and milled). Compared with other measurement methods, it is accurate, quick and credible. This system is mounted on the grinding machine and automates the measurement process by using computer control to automatically position the CCD and capture digital images of machined surfaces between grinding cycles. It was proposed that the proportional formula was used in calibrating this system, and calibration precision meets application requirement. Not only the statistic character of gray image but also which of edge image were calculated out. These characters include the mean value of pixels (Mean), standard deviation (σ), maximal value (Max) and minimal value (Min), the number of pixels on the examine line(Count), etc. It was found out that the standard deviation value σ of the gray image could express the surface roughness most. The correlation between σ and Ra is established by interpolating σ value used Lagrange interpolation law, and the σ value is converted into Ra value through the calculation procedure finally.

scholarly journals Process Capability Assessment Using Vision System

2021 ◽  
Vol 13 (2) ◽  
pp. 96-102
Author(s):  
Shivanna Dodda Mallappa ◽  
◽  
Kiran Mysore Bhaskar ◽  
Venkatesh Gude Subbaraya ◽  
Kavitha Shimoga Divakar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Vision System ◽  
Research Work ◽  
Stable Process ◽  
Process Capability ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Measuring Surface ◽  
Roughness Assessment

Surface roughness assessment would help in predicting a component’s functionality. This clearly shows the significance of measuring the surface roughness of machined components. Thus, each machined component, depending upon its intended function, requires a certain surface finish. To predict the surface roughness of a machined component, a detailed understanding of the machining parameters is essential. This is because, surface roughness generated on a component, depends upon machining parameters speed, feed, and depth of cut. A stable manufacturing process gives a consistent surface finish on all the manufactured components. Thus, only by having a stable process, consistent quality of manufactured products is possible. The capability of the machine is defined as the capability of the machine to carry out the set process efficiently and effectively to produce parts as per the specification limits. Machining parameters, tools, coolant flow rate, etc. An effort has been made in this research work, to show how by measuring surface roughness of machined components process capability can be assessed. Thus, the method is a novel technique of assessing the process capability of a given process. A capable process would help a manufacturing company in meeting customer expectations. The proposed method is of non-contact type, quick, and industry-friendly.

Surface Roughness Estimation of Turned Parts from Optical Image Measurements and Wavelet Decomposition

2014 ◽  
Vol 1 (1) ◽  
pp. 48-72
Author(s):  
R. Kamguem ◽  
A. S. Tahan ◽  
V. Songmene
Keyword(s):  
Surface Roughness ◽  
Vision System ◽  
A Priori ◽  
Measuring Method ◽  
Statistical Characteristics ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Significant Information ◽  
Turned Parts ◽  
The Impact

The surface roughness is very significant information required for product quality on the field of mechanical engineering and manufacturing, especially in aeronautic. Its measurement must therefore be conducted with care. In this work, a measuring method of the surface roughness based on machine vision was studied. The authors' use algorithms to evaluate new discriminatory features thereby than the statistical characteristics using the coefficients of the wavelet transform and used to estimate the roughness parameters. This vision system allows measuring simultaneously several parameters of the roughness at the same time, order to meet for the desired surface function used. The results were validated on three different families of materials: aluminum, cast iron and brass. The impact of material on the quality of the results was analyzed, leading to the development of multi-materials. The study had shown that several roughness parameters can be estimated using only features extracted from the image and a neural network without a priori knowledge of the machining parameters.

Comparison of Surface Roughness Attainable in High Speed End Milling of Silicon with Air Blowing on Conventional and CNC Milling Machines

2012 ◽  
Vol 576 ◽  
pp. 19-22
Author(s):  
A.K.M. Nurul Amin ◽  
Siti Nurshahida Mohd Nasir ◽  
Noor Syairah Khalid ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Compressed Air ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ductile Mode ◽  
Milling Machines ◽  
Air Blowing ◽  
Machined Surfaces

Review of past research indicated that ductile mode machining of silicon can produce surface roughness values as low as 0.22 µm, which is about half of 0.40 µm, the usual standard roughness value to avoid fine grinding and rough polishing operations. The current research investigated and compared the surface roughness and integrity attained in high speed end milling of silicon (using diamond coated tools) under ductile mode machining conditions. Two different types of end milling machines were utilized, CNC and conventional milling machines. Additionally, the effect of compressed air on the resultant surface roughness was investigated. The air blowing fixture, designed for mounting the compressed air hose, consisted of fixed and movable jaws, air blower clamp, fasteners, and the air gun. Air blowing was used to prevent silicon chips from settling on the machined surface, since it was observed to be an acute problem in high speed ductile mode machining of silicon. The three machining parameters: spindle speed, depth of cut, and feed rate were varied within the ranges 60,000 to 80,000 rpm, 10 to 20 µm, and 5 to 15 mm/min respectively. The resultant machined surfaces were analysed using Wyko NT 1100 and SurfTest SV-500 profilometers in order to measure the attaine surface roughnesses and surface profile. The machined surfaces had almost no deposition and was of excellent finish.

Influence of Machining Parameters on 3D Surface Roughness of Powder Bushings

2016 ◽  
Vol 721 ◽  
pp. 378-382 ◽  
Author(s):  
Viktor Mironov ◽  
Pavels Stankevics ◽  
Artis Kromanis ◽  
Janis Lungevics
Keyword(s):  
Surface Roughness ◽  
Powder Processing ◽  
Cutting Speed ◽  
Machining Parameters ◽  
High Porosity ◽  
Machined Surface ◽  
3D Surface Roughness ◽  
Mo Content ◽  
Machined Surfaces

The paper presents the results on research of machining anti-friction bushings of lever brake systems of rail transport, wherein the bushings are made of powder material based on iron and copper. Powder composition contains Fe-C-Cu with Ni and Mo content of less than 0.3%, and with reduced phosphorus content. The porosity of the bushings were in the range of 15 – 20 %. The main objective of the work was to determine the optimal machining parameters, as well as to evaluate the quality of the machined surface. The bushing were machined with cutting speed in the range of 130 – 150 m/min. To assess the quality of the machined surfaces the 3D roughness parameters were used, which allow to asses the surface roughness in more accurate details. The microstructure of the samples indicated the presence of pores onto the machined surfaces. It was found that to improve the quality of the surface it is necessary to adjust the parameters of the powder processing of parts with high porosity in the direction of their reduction. Studies of the microstructure and morphology of chips showed that the shape and structure of the chip is highly dependent on the porosity of the material and its processing conditions.

scholarly journals The Optimization of Machining Parameters on Surface Roughness for AISI D3 Steel

2021 ◽  
Vol 1874 (1) ◽  
pp. 012063
Author(s):  
Khair Khalil ◽  
A. Mohd ◽  
C. O. C. Mohamad ◽  
Y. Faizul ◽  
S Zainal Ariffin
Keyword(s):  
Surface Roughness ◽  
Machining Parameters ◽  
Aisi D3 Steel

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

In Situ: A Novel Approach for the Production of Micro Holes

2010 ◽  
Vol 126-128 ◽  
pp. 885-890
Author(s):  
K.P. Somashekhar ◽  
N. Ramachandran ◽  
Jose Mathew
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Machining Parameters ◽  
Average Roughness ◽  
Arithmetic Average ◽  
Quantitative Correlation ◽  
Good Surface ◽  
Novel Approach ◽  
Micro Holes

This work is on the preparation of microelectrodes for μ-EDM operation using μ-WEDG process. Electrodes of Ø500 μm are fabricated with various discharge energy machining conditions. Effects of gap voltage, capacitance & feed rate on the surface finish of the electrodes and overcut of the thus produced micro holes are investigated. The profile of microelectrodes is measured using surface roughness tester with 2μm stylus interfaced with SURFPAK software. The study demonstrated that for brass electrodes an arithmetic average roughness value as low as 1.7μm and an overcut of 3 µm could be achieved. The significant machining parameters are found using ANOVA. Surface of the produced microelectrodes are examined using Scanning Electron Microscope. μ-WEDG process parameters could be adjusted to achieve good surface integrity on microelectrodes. Experimental results showed that the surface roughness of microelectrodes depended primarily on feed rate of the electrode. The observations showed the clear and quantitative correlation existing between the micrometer level surface quality and process parameters. The resulting microelectrodes are found to be of exceptionally high quality and could be used for μ- EDM operation on different types of work materials.

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