Analysis and Verification of Surface Roughness Constitution Model After Machining Process

The process of surface roughness formation is complex and dependent on numerous factors. The analysis of the latest reports on the subject shows that mathematical relationships used for determining surface irregularities after turning and milling are not complete or accurate enough and, therefore, n...

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Bibliographic Details
Published in:Procedia engineering 2012, Vol.39, p.395-404
Main Authors: Miko, Edward, Nowakowski, Łukasz
Format: Article
Language:English
Subjects:
Finishing
Metal cutting
Surface roughness modeling
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Summary:The process of surface roughness formation is complex and dependent on numerous factors. The analysis of the latest reports on the subject shows that mathematical relationships used for determining surface irregularities after turning and milling are not complete or accurate enough and, therefore, need to be corrected. A new generalized mathematical model of roughness formation was developed for surfaces shaped with round-nose tools. The model provides us with a quantitative analysis of the effects of the tool representation, undeformed chip thickness, tool vibrations in relation to the workpiece, tool runout (for multicutter tools) and, indirectly, also tool wear. This model can be used to prepare separate models for most of the typical machining operations. Surface roughness is represented here by two parameters Ra and Rt. Simulations carried out for this model helped to develop nomograms which can be used for predicting and controlling the roughness Ra of surfaces sculptured by face milling. The paper contains also verification of the mathematical model for surfaces sculptured by face milling.
ISSN:1877-7058
1877-7058
DOI:10.1016/j.proeng.2012.07.043