Characterization of Topography of Cut Surface Based on Theoretical Roughness Indexes

2011 ◽  
Vol 496 ◽  
pp. 194-199 ◽  
Author(s):  
Csaba Felhő ◽  
János Kundrák
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tribological Properties ◽  
Significant Influence ◽  
Machined Surface ◽  
Edge Geometry ◽  
Mathematical Relation ◽  
Cut Surface

The microgeometry of cut surfaces is one important characteristic of surface quality, since it has significant influence on the tribological properties of working surfaces. In addition to the ability to plan the economical effectiveness of cutting and the accuracy of workpieces the ability to plan the quality of machined surfaces has also emphasized importance. This is why the predictability of surface roughness in planning of technological processes is more and more important. More and more opportunities presenting themselves and one of these is the estimation of the expected value of roughness of the machined surface on the basis of the theoretical value of roughness. The paper focuses on the introduction of a method to describe a mathematical relation between the theoretical and the measured roughness indexes in cutting with tools having defined edge geometry, thus the planning may be more accurate.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

scholarly journals SURFACE QUALITY OF PERUVIAN AMAZON WOODS SUBMITTED FOR PLANNING AND SANDING

FLORESTA ◽  
2019 ◽  
Vol 49 (4) ◽  
pp. 671 ◽  
Author(s):  
Miguel Meléndez Cárdenas ◽  
Claudio Gumane Francisco Juizo ◽  
Neptalí Bustamante Guillén ◽  
Hector Enrique Gonzáles Mora ◽  
Ricardo Jorge Klitzke ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Wood Surface ◽  
Cutting Planes ◽  
Processing Conditions ◽  
Peruvian Amazon ◽  
Machined Surface ◽  
Industrial Processing ◽  
Needle Detection

The present study aimed to evaluate the quality of the machined surface of wood of Peruvian Amazonian species under industrial processing conditions. For this, planks of capirona (Calycophyllum spruceanum), cachimbo (Cariniana domestica) and copaíba (Copaifera paupera) were obtained from which four specimens of each species were removed and selected. The specimens were previously conditioned and subsequently submitted to planing and sanding operations, considering three cutting orientations (tangential, radial and intermediate). Then, the quality of the flattened and sanded surfaces of the studied species was evaluated by measuring the surface roughness (Ra) by means of a digital needle detection roughness meter. The results indicated significant differences in wood surface quality among the species in the three evaluated cutting planes, and the capirona radial plane had better planing and sanding quality. Concomitantly, due to the operations performed, the capirona wood allowed a greater possibility for better finishing, followed by cachimbo and copaíba wood, thus being grouped in the 1st, 2nd, and 3rd surface quality classes, respectively.

Dry WEDM in Improving LS-WEDMed Surface Quality

2008 ◽  
Vol 53-54 ◽  
pp. 387-392 ◽  
Author(s):  
Tong Wang ◽  
Yu Mei Lu ◽  
Shu Qiang Xie ◽  
Shuang Shuang Hao ◽  
H. Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Dry Wedm ◽  
Cut Surface ◽  
Discharge Gap

Utilizing gas as the dielectric instead of dielectric liquid has enabled the development of dry wire electrical discharge machining (dry WEDM) technology for finishing cut. Experiment results showed that Low-Speed WEDM (LS-WEDM) in gas offers advantages such as better straightness, and shorter discharge gap. This paper studies on influence of different gas dielectrics, wire winding speed and pulse duration on the WEDMed surface quality (discharge gap, straightness, surface roughness, removal rate) in finishing. New attempt of applying dry WEDM as the 4th cut had been proved feasible in improving conventional multiple cut surface quality of LS-WEDM.

scholarly journals Investigation of Surface Quality for Minor Scale Diameter of Biodegradable Magnesium Alloys during the Turning Process Using a Different Tool Nose Radius

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1174
Author(s):  
Sophal Hai ◽  
Hwa-Chul Jung ◽  
Won-Hyun Shim ◽  
Hyung-Gon Shin
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Turning Process ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Nose Radius

The main objective of the study is to analyze the various cutting parameters to investigate the surface quality of the minor scale diameter of magnesium alloy in the dry turning process using a different tool nose radius (r). The surface roughness (Ra) was gauged, and micro-images produced by scanning electron microscopy (SEM) were reviewed to evaluate the machined surface topography. The analysis of variance (ANOVA), linear regression model and signal-to-noise (S/N) ratio were applied to investigate and optimize the experimental conditions for surface roughness. The study results imply that the feed rate and tool nose radius significantly affected the surface quality, but the spindle speed did not. The linear regression model is valid to forecast the surface roughness. The cutting parameters for optimum surface quality are a combination of a spindle speed of 710 rpm, a feed rate of 0.052 mm/rev and a tool nose radius of 1.2 mm. The machined surface topography contains the feed marks, micro-voids, material side and material debris, but they become smaller and decrease at a lower feed rate, larger tool nose radius and higher spindle speed. These results show the good surface quality of magnesium alloys in a dry turning process, which could be applied in implant, orthopedic and trauma surgery.

Modeling of surface roughness for manufactured thin-walled structure

2018 ◽  
Vol 233 (4) ◽  
pp. 1216-1223 ◽  
Author(s):  
Jixiong Fei ◽  
Bin Lin ◽  
Shuai Yan ◽  
Mei Ding ◽  
Jin Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Dynamic Deformation ◽  
Low Frequency ◽  
Experimental Results ◽  
Superposition Method ◽  
Milling Force ◽  
Machined Surface ◽  
Thin Walled

Deformation of thin-walled structure during machining will influence the surface quality of the final part. Present article investigates this problem and develops a method to predict the surface roughness of the machined surface. To achieve this, the prerequisite is to obtain the dynamic deformation along the milling path. To calculate it accurately, the workpiece is simplified as thin-walled shell and the milling force is simplified as moving input. An expression of the dynamic deformation of the whole structure, which under the excitation of moving milling force, is derived by solving the vibration equation using modal superposition method. Then, the deformation along the milling path is computed by substituting the path coordinates into the expression. The deformation along the milling path is filtered to remove its low-frequency and mid-frequency signals before it is used to evaluate the surface roughness of the machined surface. At last, several machining cases are implemented to demonstrate the proposed method. The experimental results match well with the predicted results. From the predicted and experimental results, it is founded that the deformation during processing is the main reason leading to the poor surface quality of the flexible machined workpiece.

scholarly journals Experimental Research on the Surface Quality of Milling Contour Bevel Gears

2021 ◽  
Author(s):  
Mingyang Wu ◽  
Jianyu Zhang ◽  
Chunjie Ma ◽  
Yali Zhang ◽  
Yaonan Cheng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Defects ◽  
Low Noise ◽  
Tooth Surface ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Bevel Gears ◽  
Machined Surface Roughness

Abstract Contour bevel gears have the advantages of high coincidence, low noise and large bearing capacity, which are widely used in automobile manufacturing, shipbuilding and construction machinery. However, the quality of the tooth surface has a significant impact on the transmission accuracy of the gear, so it is of great significance to optimize the surface quality of the contour bevel gear. This paper firstly analyzes the formation process of machined surface roughness of contour bevel gears on the basis of generating machining method, and dry milling experiments of contour bevel gears are conducted to analyze the effects of cutting speed and feed rate on the machined surface roughness and surface topography of the workpiece. Then, the surface defects on the machined surface of the workpiece are studied by SEM, and the causes of the surface defects are analyzed by EDS. After that, XRD is used to compare the microscopic grains of the machined surface and the substrate material for diffraction peak analysis, and the effect of cutting parameters on the microhardness of the workpiece machined surface is investigated by work hardening experiment. The research results are of great significant for improving the machining accuracy of contour bevel gears, reducing friction losses and improving transmission efficiency.

Machined Surface Quality of Pre-Sintered Hardenable PM Steel

2015 ◽  
Vol 659 ◽  
pp. 335-339 ◽  
Author(s):  
Thawatchai Khantisitthiporn ◽  
Monnapas Morakotjinda ◽  
Bhanu Vetayanugul ◽  
Ruangdaj Tongsri
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Texture ◽  
Depth Of Cut ◽  
Hydraulic Pressure ◽  
Average Surface Roughness ◽  
Machined Surface ◽  
Average Surface ◽  
Machined Surface Quality

The benefit of pre-sintered machining is to avoid machining difficulty of sintered parts especially hardenable PM steels. Pre-sintering treatments of green PM part at temperatures lower than the normal sintering temperature of 1120 °C result in green strength improvement high enough for machining. In this study, the influences of various pre-sintering temperatures and several machining conditions on machined surface quality of pre-sintered PM samples were investigated. The pre-sintered samples were machined by a turning process using a carbide cutting insert with varied cutting speeds at a fixed feed rate and depth of cut without cutting lubricant. Chromium alloyed PM steel (Astaloy® CrM) powder samples with (0.5 wt. %C) and without graphite (0 wt. % C) additions mixed with 1 wt. % of zinc stearate were prepared as green parts by cold compaction in a cylindrical die with diameter of 30 mm. Green density was about 7.00 g/cm3 and height of each sample was controlled by hydraulic pressure and powder weight of 80 g/sample. The green samples were treated by pre-sintering treatment before machining testing. Surface quality of each machined sample was evaluated by average surface roughness and surface texture by SEM analysis and the appearance of outlet edge breakout. The experimental results revealed that the pre-sintered samples with graphite addition showed better surface quality in terms of surface roughness and surface texture and small outlet edge breakout appearance. Moreover, at high pre-sintering temperatures of 900 and 1,000°C, the samples showed similar average surface roughness under the same turning conditions. The obtained surface textures were better than those of the samples pre-sintered at 700 and 800°C. The outlet edge breakout could not be found in the graphite-added samples pre-sintering at 1,000°C.

Observation in the Surface Roughness of Silicon Wafer during Semi-Fixed Abrasive Machining with Large Grains

2009 ◽  
Vol 69-70 ◽  
pp. 253-257
Author(s):  
Ping Zhao ◽  
Jia Jie Chen ◽  
Fan Yang ◽  
K.F. Tang ◽  
Ju Long Yuan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Silicon Wafer ◽  
Processing Parameters ◽  
Wafer Surface ◽  
Abrasive Machining ◽  
Fixed Abrasive ◽  
Is Failure ◽  
Better Than

Semi-fixed abrasive is a novel abrasive. It has a ‘trap’ effect on the hard large grains that can prevent defect effectively on the surface of the workpiece which is caused by large grains. In this paper, some relevant experiments towards silicon wafers are carried out under the different processing parameters on the semi-fixed abrasive plates, and 180# SiC is used as large grains. The processed workpieces’ surface roughness Rv are measured. The experimental results show that the surface quality of wafer will be worse because of higher load and faster rotating velocity. And it can make a conclusion that the higher proportion of bond of the plate, the weaker of the ‘trap’ effect it has. Furthermore the wet environment is better than dry for the wafer surface in machining. The practice shows that the ‘trap’ effect is failure when the workpiece is machined by abrasive plate which is 4.5wt% proportion of bond in dry lapping.

The mechanism of process parameters influencing the AlSi10Mg side surface quality fabricated via laser powder bed fusion

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Shimin Dai ◽  
Hailong Liao ◽  
Haihong Zhu ◽  
Xiaoyan Zeng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Laser Power ◽  
Side Surface ◽  
Laser Powder Bed Fusion ◽  
Scanning Velocity ◽  
Content Type ◽  
Powder Bed

Purpose For the laser powder bed fusion (L-PBF) technology, the side surface quality is essentially important for industrial applicated parts, such as the inner flow parts. Contour is generally adopted at the parts’ outline to enhance the side surface quality. However, the side surface roughness (Ra) is still larger than 10 microns even with contour in previous studies. The purpose of this paper is to study the influence of contour process parameters, laser power and scanning velocity on the side surface quality of the AlSi10Mg sample. Design/methodology/approach Using L-PBF technology to manufacture AlSi10Mg samples under different contour process parameters, use a laser confocal microscope to capture the surface information of the samples, and obtain the surface roughness Ra and the maximum surface height Rz of each sample after analysis and processing. Findings The results show that the side surface roughness decreases with the increase of the laser power at the fixed scanning velocity of 1,000 mm/s, the side surface roughness Ra stays within the error range as the contour velocity increases. It is found that the Ra increases with the scanning velocity increasing and the greater the laser power with the greater Ra increases when the laser power of contour process parameters is 300 W, 350 W and 400 W. The Rz maintain growth with the contour scanning velocity increasing at constant laser power. The continuous uniform contour covers the pores in the molten pool of the sample edge and thus increase the density of the sample. Two mechanisms named “Active adhesion” and “Passive adhesion” cause sticky powder. Originality/value Formation of a uniform and even contour track is key to obtain the good side surface quality. The side surface quality is determined by the uniformity and stability of the contour track when the layer thickness is fixed. These research results can provide helpful guidance to improve the surface quality of L-PBF manufactured parts.

Evaluation of Surface Integrity in Electrochemical Micromachining of A286 Super alloy

2021 ◽  
Author(s):  
Rajkeerthi E ◽  
Hariharan P
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Integrity ◽  
Research Work ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Dissolution Mechanism ◽  
Machined Surface ◽  
Micro Holes ◽  
Super Alloy

Abstract Surface integrity of micro components is a major concern particularly in manufacturing industries as most geometry of the products must meet out necessary surface quality requirements. Advanced machining process like electrochemical micro machining possess the capabilities to machine micro parts with best surface properties exempting them from secondary operations. In this research work, different electrolytes have been employed for producing micro holes in A286 super alloy material to achieve the best surface quality and the measurement of surface roughness and surface integrity to evaluate the machined surface is carried out. The machined micro hole provides detailed information on the geometrical features. A study of parametric analysis meant for controlling surface roughness and improvement of surface integrity has been made to find out the suitable parameters for machining. The suitability of various electrolytes with their dissolution mechanism and the influence of various electrolytes have been thoroughly studied. Among the utilized electrolytes, EG + NaNO3 electrolyte provided the best results in terms of overcut and average surface roughness.

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