Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Applicability of Diamond-Coated Tools for Ball End Milling of Sintered Tungsten Carbide

2020 ◽  
Vol 14 (1) ◽  
pp. 18-25
Author(s):  
Haruhiko Suwa ◽  
Soushi Sakamoto ◽  
Masafumi Nagata ◽  
Kazuhiro Tezuka ◽  
Tetsuo Samukawa ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
End Milling ◽  
High Hardness ◽  
High Heat ◽  
Point Of View ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Sintered Tungsten

Sintered tungsten carbide which has high hardness and high heat resistance, has been widely used in molds and dies. Research on the development of a cutting technology for sintered tungsten carbide (sintered WC-Co alloy) has been pursued mainly with the use of a turning process. We focused on building an efficient milling method for sintered tungsten carbide by using diamond-coated ball end tools, and have investigated their basic properties under specific cutting conditions. This study extends our previous work by enhancing cutting distance in the milling of sintered tungsten carbide, especially that with a “fine” WC grain. The surface roughness of cut workpieces is evaluated from the point of view of the quality of surface roughness. A series of cutting experiments under different cutting conditions were carried out, and the possibility of deriving a suitable cutting condition for the ball end milling of sintered tungsten carbide is discussed.

The Investigation of Prediction Surface Roughness from Machining Forces in End Milling Processes

2011 ◽  
Vol 486 ◽  
pp. 91-94 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Irregular Waves ◽  
Depth Of Cut ◽  
End Mill ◽  
Machined Surface ◽  
Machining Forces ◽  
Mill Cutter

Surface roughness is one of the most significant parameters to determine quality of machined parts. Surface roughness is defined as a group of irregular waves in the surface, measured in micrometers (μm). Many investigations have been performed to verify the relationship between surface roughness and cutting parameters such as cutting speed, feed rate and depth of cut. To predict the surface produced by end milling, surface roughness models have been developed in this paper using the machining forces by assuming the end mill cutter as a cantilever beam rigidly or semi- rigidly supported by tool holder. An Aluminium workpiece and solid carbide end mill tools are used in this work. Model to predict surface roughness has been developed. Close relationship between machined surface roughness and roughness predicted using the measured forces signals.

Effects of Cutting Conditions on the Machinability of Stainless Steel Formed by Laser Cladding

2013 ◽  
Vol 797 ◽  
pp. 166-171
Author(s):  
Bing Wang ◽  
Zhan Qiang Liu ◽  
Lun Chang Su ◽  
Lin Qing Zhang
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Laser Cladding ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Corner Radius ◽  
1045 Steel

The paper investigates the effects of cutting conditions on the machinability of stainless steel coatings manufactured onto AISI 1045 steel by laser cladding technology. Two kinds of CBN (cubic boron nitride) tools with different corner radius and two different depths of cut were adopted in the experiments. Cutting force during machining, surface roughness and microhardness of machined surface were measured and analyzed. The results show that both the cutting force and surface roughness increase with the increase of depth of cut. When the other cutting parameters are identical, the surface roughness decreases with the increase of tools corner radius while the variations of different cutting force components present different tendencies. The microhardness of the machined surface and its varied gradient in the direction of depth of cut increase with the increase of tools corner radius. The experiment results will provide valuable suggestions for optimization of cutting performance for laser cladding coatings in order to obtain excellent surface quality.

Study on Surface Roughness in Micro End Milling of Mold Material

2011 ◽  
Vol 325 ◽  
pp. 594-599 ◽  
Author(s):  
Hiroo Shizuka ◽  
Koichi Okuda ◽  
Masayuki Nunobiki ◽  
Yasuhito Inada
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Cutting Conditions ◽  
Mold Material ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Radial Depth ◽  
Micro End Milling ◽  
End Milling Process

The effects of cutting conditions on the surface roughness in a micro-end-milling process of a mold material are described in this paper. Micro-end-milling operations were performed under different cutting conditions such as feed rate and depth of cut, in order to investigate the factors that had the greatest influence on the finished surface during micro-end-milling. It was revealed that the surface roughness begins to deteriorate when the radial depth of the cut exceeds the tool radius. In addition, it was found that this phenomenon is peculiar to micro-end-milling processes.

Study on the Machined Surface Geometry Generated by Multi-Axis Ball End Milling Process

2013 ◽  
Vol 770 ◽  
pp. 370-375
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao ◽  
Yong Wang Dong ◽  
Shuai Liu ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Parameters ◽  
Peak Height ◽  
Milling Process ◽  
Depth Of Cut ◽  
Small Range ◽  
Surface Geometry ◽  
Machined Surface ◽  
Two Parameters

This paper investigated the surface generated by single factor experiment under multi-axis finish milling condition, and the effects of cutting parameters on surface textures, 2D and 3D surface topographies and surface roughness characteristics were analyzed. Surface features evaluation indicators of Ra, Rq, Rt, surface heights histogram, maximum valley depth and maximum peak height corresponding to various cutting parameters were presented and discussed. The machining marks are closely related with tool orientation angles. The orderly distributions of concave and convex patterns on the machined surface are produced by the special cutting orientation of the cutting edges. The feed per tooth, spindle speed, tilt angle, and lead angle apparently affect surface roughness, while depth of cut and radial width of cut have no obvious effects on the surface roughness when the two parameters values vary in a small range.

Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting

2011 ◽  
Vol 418-420 ◽  
pp. 1428-1434 ◽  
Author(s):  
Keerati Karunasawat ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Tool Diameter ◽  
End Milling Process

The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Prediction and Investigation of Surface Response in High Speed End Milling of Ti-6Al-4V and Optimization by Genetic Algorithm

2009 ◽  
Vol 83-86 ◽  
pp. 1009-1015 ◽  
Author(s):  
S. Alam ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari ◽  
Mohamed Konneh
Keyword(s):  
Experimental Data ◽  
Genetic Algorithm ◽  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Flat End Milling ◽  
Five Axis

In this study, statistical models were developed using the capabilities of Response Surface Methodology (RSM) to predict the surface roughness in high-speed flat end milling of Ti-6Al-4V under dry cutting conditions. Machining was performed on a five-axis NC milling machine with a high speed attachment, using spindle speed, feed rate, and depth of cut as machining variables. The adequacy of the model was tested at 95% confidence interval. Meanwhile, a time trend was observed in residual values between model predictions and experimental data, reflecting little deviations in surface roughness prediction. A very good performance of the RSM model, in terms of agreement with experimental data, was achieved. It is observed that cutting speed has the most significant influence on surface roughness followed by feed and depth of cut. The model can be used for the analysis and prediction of the complex relationship between cutting conditions and the surface roughness in flat end milling of Ti-6Al-4V materials. The developed quadratic prediction model on surface roughness was coupled with the genetic algorithm to optimize the cutting parameters for the minimum surface roughness.

Experimental Study on Milling Hardened SKD Steel Using Micro CBN Ball-End Mills

2010 ◽  
Vol 126-128 ◽  
pp. 773-778
Author(s):  
Yung Tien Liu ◽  
Neng Hsin Chiu ◽  
Yen Chun Lin ◽  
Chih Liang Lai ◽  
Yu Fu Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Machined Surface ◽  
Performance Function ◽  
End Mills

Micro ball-end milling process features the ability of machining complex surfaces, precision machining accuracy, and excellent machined surface roughness. However, because the diameter of a micro milling tool is very small, a rapid progress of tool wear or even tool breakage usually happens when machining a high-strength hardened mold steel using improper machining parameters. As a result, the machining cost would rise due to the quality defect in machined workpiece. In this study, to investigate how the machining parameters affect the cutting behaviors, a series of experiments using micro CBN ball-end mills with a diameter of 0.5 mm were performed to cut the SKD11 mold steel with hardness of HRC 61. The machining parameters are selected as the feeding speed (f) being 840, 960 and 1,080 mm/min, depth of cut (ap) being 30, 45, 60 μm, and spindle speed (vs) being fixed as 30,000 rpm. According to the experimental results, the measured three-axis cutting forces, flank wears, and surface roughness of machined workpiece are highly related to the cutting length. It is expected that the measured results can be used to construct a performance function of a micro ball-end tool. With referring to the performance function, the tool life can be well expected, and thus a progress in machining efficiency without tool failure can be achieved.

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