Modeling for Prediction of Surface Roughness and Experimental Research in Ultra-Precision Flycutting Machining

2018 ◽  
Author(s):  
Jiasheng Li ◽  
Yang Jiao ◽  
Pinkuan Liu
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Set Up ◽  
Validation Tests ◽  
The Relationship

To improve the surface quality of the copper and reduce the diamond tool wear, a prediction model is established experimentally for the relationship between surface roughness and machining parameters. Based on the processing principle of flycutting machining, the prediction model for surface roughness is set up by response surface methodology. Then, a machining experiment for the copper is conducted under different cutting parameters designed by Taguchi method and the surface roughness is tested by 4D technology dynamic laser interferometer. After that, the prediction model is obtained by analyzing the experimental data, and the accuracy of the model is verified by analysis of variance (ANOVA), R2 value and residual analysis. Furthermore, the effect of cutting parameters upon the surface roughness is analyzed. Finally, validation tests are conducted to verify the model. Experimental results demonstrate that the prediction model is adequate at 95% confidence level. The output of prediction model helps to select cutting parameters to reduce surface roughness which ensures surface quality in ultra-precision fly cutting machining.

EVALUATION OF A REGRESSION PREDICTION MODEL FOR SURFACE ROUGHNESS OF WOOD–POLYETHYLENE COMPOSITE (WPC)

2017 ◽  
Vol 24 (Supp02) ◽  
pp. 1850033
Author(s):  
WENYONG SHI ◽  
YAN MA ◽  
CHUNMEI YANG ◽  
BIN JIANG ◽  
ZHE LI
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Prediction Model ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Wood Powder ◽  
Polyethylene Composite ◽  
Milled Surface ◽  
Powder Content

Milling processing is an important way to obtain wood–polyethylene composite (WPC) end products. In order to improve the processing efficiency and surface quality of WPC and meet the practical application requirements, this paper focussed on morphology and roughness of the WPC-milled surface and studied surface quality changes under different cutting parameters and milling methods through multi-parameters milling experiments. The milling surface morphology and roughness of WPC were analyzed and measured during cut-in, cutting and cut-out sections. It also revealed the affect rule of different cutting parameters and milling methods on milled surface morphology and roughness. The results show that the milling surface roughness of WPC products with wood powder content of 70% is significantly larger than the one whose wood powder content is 60%, and defects such as holes are also relatively more. Finally, a surface roughness prediction model was established based on the mathematical regression method and its multi-factor simulation was carried out. A comparative analysis of predictive and experimental values was performed to verify the reliability of the model. It could also provide theoretical guidance and technical guarantee for high processing quality of WPC milling and cutting.

Study on Surface Roughness Based on Dynamic Minimum Thickness of Cut

2011 ◽  
Vol 88-89 ◽  
pp. 34-37
Author(s):  
Kuai Ji Cai
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Atomic Force Microscope ◽  
Surface Quality ◽  
Experimental Verification ◽  
Cutting Parameters ◽  
Minimum Thickness ◽  
Atomic Force ◽  
Relationship Of ◽  
The Relationship

The relationship of the friction coefficient and the MTC were discussed, and the MTC and its effects on surface roughness were a theoretical analysised and experimental verification by AFM (atomic force microscope). The results show that the theoretical MTC tends to be minimal value then before the adhering effect to reach remarkable. Appropriate adjustments cutting parameters, the cutting process can always micro-cutting phase to reach the steady-thin chip, and no plowing phenomenon. So the surface residues highly were reduced and higher surface quality was achieved.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Study on Surface Roughness of Milling In-Situ TiB2 Particle Reinforced Al Matrix Composites

2019 ◽  
Author(s):  
Xiao-fen Liu ◽  
Wen-hu Wang ◽  
Rui-song Jiang ◽  
Yi-feng Xiong ◽  
Kun-yang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Cutting Depth

Abstract The current state of surface roughness focuses on the 2D roughness. However, there are shortcomings in evaluating surface quality of particle reinforced metal matrix composites using 2D roughness due to the fact that the measuring direction has a vital impact on the 2D roughness value. It is therefore of great importance and significance to develop a proper criterion for measuring and evaluating the surface roughness of cutting particle reinforced metal matrix composites. In this paper, an experimental investigation was performed on the effect of cutting parameters on the surface roughness in cutting in-situ TiB2/7050Al MMCs. The 2D roughness Ra, 3D roughness Sa and Sq were comparatively studied for evaluating the machined surface quality of in-situ TiB2/7050Al MMCs. The influence of cutting parameters on the surface roughness was also analyzed. The big difference between roughness Ra measured along cutting and feed directions showed the great impact of measuring direction. Besides, surface defects such as pits, grooves, protuberances and voids were observed, which would influence 2D roughness value greatly, indicating that 3D roughness was more suitable for evaluating surface quality of cutting in-situ TiB2/7050Al MMCs. The cutting depth and feed rate were found to have the highest influence on 3D roughness while the effect of cutting speed was minimal. With increasing feed rate, cutting depth or width, the 3D roughness increased accordingly. But it decreased as cutting speed increased.

scholarly journals Pseudo-random Path Generation Algorithms and Strategies for the Surface Quality Improvement of Optical Aspherical Components

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1216
Author(s):  
Jun Zha ◽  
Hangcheng Zhang ◽  
Yipeng Li ◽  
Yaolong Chen
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Path Generation ◽  
Optical Components ◽  
Validation Experiment ◽  
Polishing Path ◽  
Computer Controlled Optical Surfacing ◽  
The Relationship ◽  
Convolution Effect

This study proposes two path generation algorithms to diminish the superposition of the convolution effect on the polishing path in computer-controlled optical surfacing. According to the polishing of aluminum-alloy based hyperboloid optical components, different proportions of polishing agents were blended. Then, the surface roughness of the optical components were determined through a validation experiment of the algorithms. Furthermore, the relationship between surface roughness and the polishing agent concentration, and the compensation strategies for surface roughness were analyzed. The results show that the two algorithms effectively compensated for surface waviness. The findings support the strategies for improving the surface quality of optical components with aspherical surfaces.

scholarly journals A Proposed Scan Strategy Used on SLM Inner Structure Part

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 937 ◽  
Author(s):  
Jitai Han ◽  
Meiping Wu ◽  
Weipeng Duan
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Laser Energy ◽  
Side Surface ◽  
Test Results ◽  
New Strategy ◽  
Optimal Surface ◽  
The Relationship ◽  
Main Factor

A model with an inner structure was designed to study the relationship between the surface quality of the inner structure and the scan strategy in this study. The test results showed that the precision of the inner structure was highly affected by the scan strategy, and the specimens printed using different strategies showed different performances on the surface quality of the inner structure. The specimen printed using the square-framed scan strategy had a lower flatness value on the positive face of the inner structure compared to that of the other two specimens printed using Z-shape scan strategies, while the specimen printed using the Z-shape scan strategy (along the inner structure) had a relative optimal surface roughness on the side surface of the inner structure in all three specimens. The bending deformation caused by the scan strategies was considered to be the main factor affecting the flatness on the positive surface, while laser energy fluctuation showed a significant impact on side surface roughness. Combined with the experimental data, a new scan strategy was proposed; we found that the specimen printed using this new strategy improved positive surface flatness and side surface roughness.

Influence of Cutting Parameters on the Surface Quality of Round Parts Made from AZ61 Magnesium Alloy and Machined by Turning

2013 ◽  
Vol 837 ◽  
pp. 128-134 ◽  
Author(s):  
Gheorghe Mustea ◽  
Gheorghe Brabie
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Magnesium Alloy ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Az61 Magnesium Alloy ◽  
Machined Surfaces

The use of magnesium alloys in construction of different components of the mechanical systems (such: cars, aerospace vehicles, medical equipment etc.) is very efficient not only because it leads to reduction of the systems weight but also because it leads to reduction or elimination of the environment polluting and to reduction of the energy consumption. Generally, the main factors that influence the quality of the machined surfaces are as follows: cutting parameters, material properties, geometry of the tools, cooling liquids and lubricants, physical and mechanical properties of the subsurface layers etc. Among the above mentioned factors, cutting parameters are the factors that strongly influence the quality of the machined surfaces. The present paper analysis the results of the experimental investigation performed to determine the influence of cutting parameters (cutting speed, feed rate and cutting depth) on the surface quality machined by turning the AZ61 magnesium alloy. The main characteristics of the machined surface quality analyzed in experimental investigation were the surface roughness and hardness. The main conclusions resulted from the results analysis were as follows: the decrease of the feed rate led to surface roughness decrease and hardness increase; the increase of the cutting speed also led to an improved surface quality.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

scholarly journals Study on Surface Roughness in Micro Milling of Single Crystal Materials

2019 ◽  
Vol 1 (1) ◽  
Author(s):  
Qi Gao ◽  
Po Jin ◽  
Guangyan Guo
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Surface Quality ◽  
Feed Rate ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Micro Milling ◽  
Cemented Carbide Tool

Micro milling is a machining method of high precision and efficiency for micro components and features. In order to study the surface quality of single crystal materials in micro milling, the two-edged cemented carbide tool milling cutter with 0.4 mm diameter was used, and the orthogonal experiment was completed on the micro-milling of single crystal aluminum material. Through the analysis of statistical results, the primary and secondary factor which impacting on surface quality were found as follows: spindle speed, feed rate, milling depth. The ideal combination of optimized process parameters were obtained, when the spindle speed was 36000 r/min, the milling depth was 10 μm, the feed rate was 80 μm/s, which made the milling surface roughness is 0.782 μm and minimal. Single crystal materials removal mechanism were revealed, and the influence of cutting parameters on micro-milling surface were discussed, the reason of tool wear was analyzed. Those provide a certain theoretical and experimental basis for micro milling of single crystal materials.

scholarly journals PENENTUAN KECEPATAN PEMOTONGAN EFEKTIF BERDASARKAN NILAI KEKASARAN PERMUKAAN MATERIAL AA-7075 PADA PROSES FACE MILLING

POROS ◽  
2021 ◽  
Vol 17 (1) ◽  
pp. 51
Author(s):  
Sobron Y. Lubis ◽  
Rosehan Rosehan ◽  
Musa Law
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Tooth Development ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Parameters ◽  
Aa 7075 ◽  
Aluminum Alloy 7075

During face milling machining, several machining parameters such as feed rate and cuttingspeed determine the surface quality of the workpiece produced by the process. The selection of the rightparameters will lead to the surface quality as planned. Therefore, to improve machining effectiveness, amethod is needed to determine the appropriate machining parameters to produce the desired surfacequality. This research was conducted using a milling machine, five variations of cutting speed and fivevariations of feed rate were used to cut the workpiece aluminum alloy 7075. After machining, the surfaceroughness was measured using a surface test. The surface roughness value is then substituted into thefeed rate equation and effective cutting speed. By finding effective cutting parameters, the machiningprocess will be more efficient and effective without using unnecessary resources. From the results of thestudy note that the development equation to determine the feed rate based on the value of surfaceroughness is ???? = 0,6????√???? ????????0.443mm/tooth. Development equation to determine the effective cutting speedbased on Surface roughness value is ???????? = 3.0686????????0.124 mm/min

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