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Analysis of the geometric features and determination of the condition of the surfaces machined during an abrasive process is of crucial importance for evaluation of their wear properties. Numerous parameters can be used for assessing topography of technical surfaces. Many of them contain information that is general or poorly correlated with the wear features. The group of parameters used for such purpose should include those that do not cause information redundancy and provide distinct information. Evaluation of the surface geometric structure after precision machining is a difficult process due to the limited scope of unevenness heights that fit within the range of a few micrometers to a few nanometers. In this paper the synthetic indexes of the evaluation of extra smooth surfaces were created, taking into consideration numerous elementary parameters. The value of the synthetic index was determined as the geometric average of the partial indexes which, when compared to the arithmet...
Roughness consists of the irregularities of the surface texture, usually including those irregularities that result from the actions involved in the production process. Surface roughness is an important measure of the quality of a machined product and a factor that greatly determines manufacturing cost. In this work,in order to estimate surface quality and dimensional precision properties in advance, theoretical models are employed making it feasible to do prediction in function of operation conditions and machining parameters such as feed speed and depth of cut etc. The need for statistical method like DOE for studying the relationship between the machining parameters is because of this need for prediction. It is a analysis technique which uses the regression method to find out the relationship between various factors in a DOE setup depending upon the interactions of the predictor variables and the response variables which is performed in the experiments. The research in this domain will help advance further investigations into the relationship between the machining factors and the surface quality of the machined components. The DOE using Taguchi's method and statistical study of the experimental data helps to understand the interaction between various factors like speed, feed and depth of cut in the machining.
Manufacturing Technology, 2019
This paper deals with basic methodology of surface evaluation of functional surfaces, which were prepared by various machining methods (turning, milling and grinding). Here are the basic 2D (profile) parameters and 3D (spatial) parameters and their properties in relation to the machined surface. Parameters of machined surfaces were obtained by CCI Lite Coherence Correlation Interferometer from Taylor Hobson and evaluated using the TalyMap Platinum software. The article further demonstrates the inappropriateness of the surface structure assessment with only the parameter Ra (mean arithmetic deviation of the profile), which is the most common method in technical practice. This methodology extends the possibilities of a comprehensive assessment of exposed surfaces of machine parts.
Frontiers in Mechanical Engineering
A new concept of the effective surface profile is proposed to facilitate the prediction of the worn surface texture at sliding friction. The effective surface profile is a 2D height characteristic that consists of the asperities of surface superimposed on a plane perpendicular both to the mean surface plane and to the direction of sliding. We hope to present a clear and compelling argument favoring the use of the effective surface profile as a versatile tool for characterization of rough surfaces at abrasive wear, calculation of contact characteristic at sliding friction, and for prediction of evolution of roughness parameters from virgin to the worn surfaces. The effective surface profile can be successfully applied for investigations of sliding abrasive wear under dry or lubricated conditions.
This paper suggests a new approach to measuring surface roughness facilitated by the introduction of a new parameter, called parameter of statistic equality of sampling lengths. The procedure for obtaining the primary profile, the roughness profile and the waviness profile is presented as a set of recommendations of several ISO standards. In addition, the paper suggests the expansion of the presented measuring procedure by direct inclusion of the new parameter. Another novelty is that the proposed algorithm now allows the inclusion of feedback which thus far has not been the case in roughness measuring. The newly proposed parameter was been verified using etalons and real surfaces, representing several machining process by material removal.
Acta Technica Jaurinensis
The examination of the tribological processes can be implement by different methods. In the initial stage of the abrasive wear process, the microtopography of steels drastically changes until it reaches a stable state. This change can be described by different methods. One of the methods is the characterisation with the help of roughness parameters. In this paper validated simulation algorithm has been used to predict the modification of the roughness parameters. Manufactured microtopographies with same arithmetical mean height (Sa) value can be modelled to the destroying with the help of abrasive worn microtopography. It was found the main roughness parameters named Sa, Sq, Ssk, Sku modification strongly depending to the manufacturing technology.
2017
As a metal machining process, end milling is the most widely used processes in industry. One of the most important indicators of success in finishing operation is the estetic quality of the surface that is directly connected to the maximal height of uneven surfaces, namely rougness. In process of milling the quality of the machined surface depends of many factors, for example, tool geometry, cutter parallel axis offset and cutter axis tilt, tool deflection due to cutting forces, tool and work piece vibrations etc. This paper presents the development of mathematical model for the determination of the quality of the machined surface topography. The model starts from an ideal trochoid point trajectory on the cutting edge tooth end mill, and then inserts the deviations due to cutter parallel axis offset and cutter axis tilt and gives instructions for the input of other factors that influence on the machined surface quality. Also it compares the values of maximal roughness height with di...
This paper presents the effect of process parameter in end milling operation to predict surface roughness. An experiment has been conducted to observe the significance of process parameters and influence of the radial rake angle of the tool in end mill cutter. Mathematical model has been developed to predict surface roughness in terms of machining parameters such as spindle speed, feed rate, radial, axial depth of cut, and rake angle of cutting tool. The second-order mathematical models, in terms of the machining parameters, have been developed using Response surface methodology (RSM)by designing five factors, five level central composite rotatable design matrixes with full replication. The experiment is conducted on aluminum Al 6063 by HSS end mill cutter, the surface roughness is measured by using Surftest SJ-201.The direct and interaction effects of the machining parameter with surface roughness are analyzed using design expert software. It is found that spindle speed and radial rake angle are major factors influencing the surface roughness followed by radial depth of cut, feed rate and axial depth of cut. The developed mathematical model is verified by confirmatory test and found to be acceptable for the prediction of surface roughness.
Journal of Archaeological Science: Reports, 2022
Use-wear analysis has been a well-established aspect of the study of artefact biography for decades, and it has recently developed along two different, though complementary methodological paths. While the classical or qualitative approach still relies largely on the experience gained from the combination of experimental tests, tribological principles and visual observation, new attempts try to define quantitative surface signatures. Surface topography and roughness analyses should allow one to associate surfaces to specific uses and warrant comparability and reproducibility of obtained datasets beyond textual descriptions and images. This approach is highly relevant to use-wear studies of macrolithic tools, where different techniques have made use of the available high-resolution devices. However, no systematic approach has been published yet with the aim of evaluating the operating capacity of the different systems and techniques. Consequently, the precision as well as the resolution of the data obtained and the comparability between results is questionable because of the complexity of the available technical options. The present study offers a method for surface roughness quantification of macrolithic tools and compares the results achieved with different 3D modeling devices.
Surface is one of the most significant requirements in metal machining operations. In order to attain enhanced surface quality ,the appropriate setting of machine parameters is important before the cutting operation take place. The objective of this research is to analyze the effect of machining parameters on the surface quality of aluminum alloy in CNC milling operation with HSS tool. A multiple regression model developed with spindle speed, feed rate and depth of cut as the independent variable and surface roughness parameter 'Ra' as the dependent variable. The prediction ability of the model has been tested and analyzed using 'Mini Tap' and it has been observed that there is no significant different between the mean of 'Ra' values of theoretical and experimental data at 5% level of significance. In addition to that, they are going to use Box-Behnken designs method which is used to analyze the surface roughness and it designs when performing non-sequential experiments. That is, performing the experiment once. These designs allow efficient estimation of the first and second-order coefficients. Because boxbehnken designs have fewer design points, they are less expensive to run than central composite designs with the same number of factors.
Journal of Automation, Mobile Robotics and Intelligent Systems, 2011
High precise measurement techniques and surface structure analysis are required in advanced fields of interchangeable manufacturing and precision engineering. This study presents the characterization of the surface roughness of the machined milling cutters by experimental precision measurements and the image processing tool. The data obtained are compared to assess the surface characterization parameters and computational data in terms of precision, accuracy, sensitivity, repeatability and resolution. In the experimental measurement phase, the roughness measurements and surface topography characterization were performed in the nanotechnology laboratory using the stylus profilometry and digital microscopy. The computational phase was performed using an image processing toolbox with precise evaluation of the roughness for the machined metal surfaces of the end mill cutting tool. The surface parameter database is established exhibiting an advantage over the traditional method. This stu...
2014
In these days, the key elements for the reliability and the safe operation of technical devices are the following: surface of the tools, the surface quality and the roughness of the connecting elements. The present work is going to introduce the idea that different machining methods that create microgeometries that are very much different from each other and of diverse roughness parameter proportions. It will be shown that the wear and the change of the tool edge(s)-resulting from the deterioration process of the tools, used during production-cause significant arithmetical, average and form deviations. The uncertainties of the roughness measuring technique, arising during the evaluation of the real and filtered surface profiles, will be shown via samples.
Metrology and Measurement Systems, 2017
This paper presents a comprehensive methodology for measuring and characterizing the surface topographies on machined steel parts produced by precision machining operations. The performed case studies concern a wide spectrum of topographic features of surfaces with different geometrical structures but the same values of the arithmetic mean height Sa. The tested machining operations included hard turning operations performed with CBN tools, grinding operations with Al2O3ceramic and CBN wheels and superfinish using ceramic stones. As a result, several characteristic surface textures with the Sa roughness parameter value of about 0.2 μm were thoroughly characterized and compared regarding their potential functional capabilities. Apart from the standard 2D and 3D roughness parameters, the fractal, motif and frequency parameters were taken in the consideration.
Latvian Journal of Physics and Technical Sciences, 2014
The existing standards for surface roughness cover only two dimensions, while in reality this is three-dimensional (3D). In particular, the 3D surface roughness parameters are important for solving the contact surface mechanics problems as related to the accuracy of 3D surface roughness characteristics. One of the most important factors for determination of 3D characteristics is the number of data points (NDP) on the x- and y-axes (i.e. in cut-off length). The NDP has a profound effect on the accuracy of measurement results, measuring time and volume of the output data (especially along the y-axis, where the NDP is identical to the number of parallel profiles). At a too small NDP the results will be incorrect and with too broad scatter, while a too large NDP - though not enlarging the range of basic information - considerably increases the measuring time. Therefore, the aim of the work was to find the optimal NDP for such surface processing methods as grinding, spark erosion and sho...
Design of experiments is performed to analyse the effect of spindle speed, feed rate and depth of cut on the surface roughness of 6061 Aluminium alloy. The results of the machining experiments were used to characterise the main factors affecting surface roughness by the Analysis of Variance (ANOVA) method. The feed rate was found to be the most significant parameter influencing the surface roughness in the end milling process.
2012
This paper presents a comparison of the results for roughness parameters obtained with the help of two methods of evaluating the quality the finished surfaces: 2D profilometry and 3D profilometry. There were investigated square areas from finished steel rings and polymeric blocks, these elements being used for tests on a block-on-ring tribotester. There were calculated the average values of the 3D parameters characterizing three square areas on each part and the average values of nine 2D profiles extracted from the already investigated square areas. There also discussed the scattering ranges for the roughness parameters as given by each of the two methods. When evaluating the worn surfaces, the parameters Ssk, Sku, Sy, Sp are Sv, are more relevant, as the high peaks affects the tribological parameters, especially when dealing with polymeric composites.
Measurement Science Review, 2012
The paper deals with the measurement and identification of surfaces after machining in a non-contact manner. It presents a new modified measurement method and its implementation, the results of intensity distribution in the defocusing plane, their analysis and interpretation. The scanned intensity distribution at the defocusing plane gives information necessary to assess the second derivatives, and thus, surface functions which can be used to determine groove curvatures of the real surface morphology. The proposed method of measurement has proved to be very sensitive in evaluating the differences between surface finishing methods by which the measured surface standards (etalons) were machined. Two methods of machining were chosen: face grinding and planning. By comparing the roughness standard values Ra, there were obtained relationships between these values and the parameter of the characteristic frequency of vertical inequality being measured according to the presented method. A good correlation between the measured and surface standard values with the correlation coefficient taking a range of values from 0.8 to 1 was achieved.
Surface Integrity in Machining, 2010
This chapter presents the basic knowledge on surface integrity produced in traditional and non-traditional machining processes. An extended overview of fundamental characteristics of surface finishes and surface integrity including surface roughness/surface topography, specific metallurgical and microstructure alterations and process-induced residual stresses is carried out. Surface roughness was determined by many important 3D roughness parameters and representative scanned surface topographies were included. They allow recognizing the structural features, i.e., determined and random components of the machined surfaces. Moreover, some practical formulae for prediction of the theoretical surface roughness in typical cutting operations (turning and milling) and grinding operations are provided. On the other hand, possible surface alterations resulting from abusive machining operations are demonstrated. Finally, the state-of-the-art of machining technology is addressed to many finishing cutting, abrasive and non-traditional (EDM, ECM, LAM, USM, etc.) operations to show how the manufacturing processes can be effectively utilized and optimized in practice.
Tribologia
The shaping of the functional properties of the surface of an object in a technological process plays a key role in the later operation of this object. The paper presents the results of the tests performed on the surface topography of objects made of a selected hard-to-machine material, i.e., titanium alloy. Two measuring devices were used in the research, an interference microscope, and a scanning electron microscope, which enabled the comprehensive (nonparametric and parametric) description of surface topography obtained for three different finishing parameters. It was noted that, in addition to material properties, in the evaluation of the functional properties of a surface, it is important to carry out not only the qualitative, but also quantitative analysis of the machined surface topography.
Metrology and Measurement Systems
Analysis of the shape and location of abrasive grain tips as well as their changes during the grinding process, is the basis for forecasting the machining process results. This paper presents a methodology of using the watershed segmentation in identifying abrasive grains on the abrasive tool active surface. Some abrasive grain tips were selected to minimize the errors of detecting many tips on a single abrasive grain. The abrasive grains, singled out as a result of the watershed segmentation, were then analyzed to determine their geometric parameters. Moreover, the statistical parameters describing their locations on the abrasive tool active surface and the parameters characterizing intergranular spaces were determined.
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