SURFACE ROUGHNESS EVALUATION IN TURNING BASED ON ABBOTT FIRESTONE CURVE
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1 SURFACE ROUGHNESS EVAUATION IN TURNING BASED ON ABBOTT FIRESTONE CURVE Adriana Carmen Cîrstoiu Materials, Equipments, Installations and Robots Department, VAAHIA University of Târgovişte, România, Abstract The paper presents experimental determination of the influence of the cutting tool nose radius on surfaces roughness in case of external turning. A roughness evaluation by its correlation with Abbott- Firestone curve and statistical distribution of the amplitudes of roughness profiles has been undertaken in the frames of this paperwork. Key words Surface Roughness, roughness profile, nose radius, Abbott - Firestone curve 1. Introduction The measurement of surface state evaluates the defects of surface inevitably generated during the manufacture of parts. A good knowledge of these defects can take the necessary steps to keep within limits acceptable to the work piece assumes the function for which it was designed in the best economic conditions [1]. The factors that play a major influence on the quality of machined surfaces are: the machining parameters, the geometry of cutting tool, the properties of the material worked, the nature and mode of lubrication, the phenomenon of work hardening and the machining method []. In this paper are presented the data on the experimental influence of tool geometry on surface quality machined by turning. It was shown by theoretical and experimental research to the favorable effect of increasing nose radius r ε on quality machined surfaces by turning, expressed by the parameters Ra and Rt. Parameters are numerical values assigned to a surface, the most common being Ra, which averages the peak and valley displacement from a mean line but provides no information about the height of the peaks and valleys or the ability of the material to bear a load (bearing ratio). A study of bearing area ratio, T p and the Abbot-Firestone curve (bearing area curve) allows the display of statistical distribution of depths of points on the profile [3]. Bearing area ratio (Tp) is the length of the bearing surface expressed as a percentage of the assessment length at a depth, or "slice level," below the highest peak [4]. It is useful because it simulates wear at various cutting depths of the surface. Ra is an important parameter of roughness, but two different surfaces may have similar Ra, but could function differently. It is therefore necessary to analyze other parameters such as Rq, Rsk or Rku [5]... Design of the experiment We measure the parameters of surface roughness machined by turning, thanks to a modified nose radius tool. Experimental investigations were conducted on cylindrical surfaces mm in length and 41 mm in diameter, separated by gorges, as illustrated by Figure 1. Fig. 1. The configuration and dimension of the machined work piece The material in cylindrical bar XC18 is a non-alloy steel low carbon (.16% -.%) C. The steel also contains: Si (, %), Mn (.4 to.7 %), P.35% S.35%. Experimental investigations were performed on a CNC machine, an NC lathe Challenger 3. The experiments consisted of processing the four areas, with mm length and initial diameter of 41 mm, with the same cutting parameters, but with different geometry of the cutting plates. Geometry of cutting plates are different because of different nose radius, r ε. The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No
2 The cutting parameters used in processing were: - Cutting speed, v c = m / min (corresponding to a speed of 1 rpm) - feed f =. mm / rev - depth of cut a p = 1.7 mm. In experiments were used the following carbide cutting plates, manufactured by Sandvik Coromant and chosen by CoroGuide and CoroKey PC programs: CNMG 144 MF ; r ε =,4 mm CNMG 148 MF ; r ε =,8 mm CNMG 141 MF ; r ε =1, mm CNMG 1416 MF ; r ε =1,6 mm -Port-plates - PCN R K1. Measuring parameters of roughness and bearing area ratio was done using a Taylor Hobson (Surtronic 3+) surface profilometer [6]. 3. Results analysis 3.1 Influence of nose radius on surface roughness Correlation between the tool geometry, feed rate f and the surface roughness is demonstrated by relationships (1) şi () [7]. f Rt teor 8 Rt teor [mm], (1) r r f r [mm] () 4 The roughness parameter Rt can be calculated with both relationships, but in this paper has used the relationship (1) and the values obtained were noted Rt theor. For situations where the tool has a radius, one can estimate the value of the parameter Ra as [8]:.31 f Ra teor [mm], (3) r where: f is the feed rate in mm / rev; r ε is the nose radius in mm; Rt is the maximum peak-to-valley height of the roughness profile; Ra represents the arithmetical mean deviation, the average roughness or deviation of all points from a plane fit to the test part surface, evaluated in accordance with ISO 487: 1. In Table 1 are the theoretical values of roughness parameter Rt, calculated with the relationship (1), very close to those calculated by equation (), the theoretical values of roughness parameter Ra, obtained using the theoretical model Boothroyd, relationship (3) and experimental values of Rt and Ra. Comparing the theoretical and experimental values of roughness parameters Ra and Rt, can see that reports values of roughness parameters are very close; the report Rt teor / Ra teor is about 4, and the report Rt exp / Ra exp is about 5, according to Table 1. It notes the existence of very small differences between experimental and theoretical values of roughness parameters Ra, so that we can say that the predicted values of the surface parameter Ra were confirmed by experimental values of Ra (table 1). Small differences between experimental and theoretical values of roughness parameter Rt is explained by the possibility of differences in cutting conditions in relation to the theoretical relationships. Table 1. Theoretical and experimental values of roughness parameters Rt and Ra for the processed surfaces with different nose radius Nose radius r ε =,4 mm r ε =,8 mm r ε =1, mm r ε =1,6 mm (Profile 7) (Profile 8) (Profile 9) (Profile 1) Roughness Parameters/ Report values R t exp [μm] 1, 7,56 6,63 4,76 R a exp [μm],16 1,51 1,16,918 R t exp / R a exp 4,7 4,344 5,715 5,185 R t theor [μm] 1,5 6,5 4,166 3,15 R a theor [μm] 3,1 1,65 1,7,8 Rt teor / Ra teor 3,894 3,894 3,893 3,96 Regarding the values of parameters Rt and Ra, we observe that the roughness values decreases, so the surface quality increases when the nose radius increases, as shown in Figure. 164 The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No. 38
3 Roughness parameters [um] Ra exp Rt exp Ra theor Rt theor Nose radius [mm] Fig.. Theoretical and experimental values of roughness parameters Rt and Ra for surfaces machined with different radiuses of tool s tip Figures 3, 4, 5 and 6 shows the profiles of surface roughness and the values of roughness parameters for the machined surfaces with the following values for the nose radius, r ε :,4 mm;,8 mm; 1, mm and 1,6 mm. The values of roughness parameters for machined surfaces with values r ε mentioned above are presented in Table 1. It is noted that the experimentally determined values of roughness parameters decrease when increasing cutting tool nose radius, confirming theoretical research from [9] and experimental research from [1]. Fig. 3. Roughness profile and the parameters of roughness achieved by nose radius r ε =,4 mm Fig. 4. Roughness profile and the parameters of roughness achieved by nose radius r ε =,8 mm The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No
4 Fig. 5. Roughness profile and the parameters of roughness achieved by nose radius r ε = 1, mm Fig. 6. Roughness profile and the parameters of roughness achieved by nose radius r ε = 1,6 mm 3. Abbot-Firestone curve and the statistical distribution of amplitudes The Abbott-Firestone bearing curve represents a surface that requires very little depth to obtain a supporting surface. The Abbott-Firestone bearing curves for machined surfaces with nose radius shown in Table are presented in Figures 7, 8, 9 and 1. Fig. 7. Curve Abbot - Firestone and the statistical distribution of amplitudes for the profile machined with the nose radius r ε =.4 mm 166 The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No. 38
5 Fig. 8. Curve Abbot - Firestone and the statistical distribution of amplitudes for the profile machined with the nose radius r ε =.8 mm The bearing ratio curve is generated by plotting a curve at various depths. The slope of this curve can be useful in determining how fast a surface will wear and the dimensional size change likely after wear-in. Table. Bearing area ratio for the processed surfaces with different nose radius Profile Parameters Profile 7 (r ε =,4 mm) Profile 8 (r ε =,8 mm) Profile 9 (r ε =1, mm) Profile 1 (r ε =1,6mm) Cutting depths of the 7,78 5,94 5,6 3,96 surface [μm] Bearing area ratio [%] Rt exp [μm] 1, 6,56 6,63 4,76 Ra exp [μm],16 1,51 1,16,918 Fig. 9. Curve Abbot - Firestone and the statistical distribution of amplitudes for the profile machined with the nose radius r ε = 1. mm The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No
6 Fig. 1. Curve Abbot - Firestone and the statistical distribution of amplitudes for the profile machined with the nose radius r ε = 1.6 mm Ra is an important parameter of roughness, but two different surfaces may have similar Ra, but could function differently. It is therefore necessary to analyze other parameters such as Rq, Rsk or Rku, defined by relations 4, 5 and 6. The values of these parameters corresponding machined surfaces with different tool noses are indicated by the roughness Surtronic 3 + and listed in Table 3. Table 3. Values of roughness parameters Rq, Rsk and Rku for the machined surfaces with different nose radius Profile Profile7(r ε =,4 mm) Profile8(r ε =,8 mm) Profile9(r ε =1, mm) Profile1(r ε =1,6mm) Rq [μm],5 1,73 1,37 1,9 Rsk (S k ),468,96,34,613 Rku (E k ) 1,99 1,85,1,39 The distribution of amplitudes of roughness profiles can approach a Gaussian distribution. The parameters we are interested: Root mean square roughness, Rq (μm), the average of the measured height deviation taken within the evaluation length or area and measured from the mean linear surface: R q 1 z ( x) dx (4) Skewness (indicator characterizing the symmetry of the profile), Rsk: Rsk z ( x) dx (5) 3 R q Kurtosis (indicator characterizing the spread of the distribution), Rku: Rku 1 1 z ( x) dx R 4 4 q (6) Skewness is a measure of symmetry of the profile about the mean line. Kurtosis is a measure of the randomness of heights and of the sharpness of a surface. Skew and kurtosis are central moments of the third and fourth order. They are able to measure the material ratio on a profile. In particular, the skew shows the degree of symmetry of the profile, while the kurtosis shows the amount of profile points near (narrow profile) or far (flat profile) from the mean. Amplitude distributions profiles presented in Figs 7, 8, 9 and 1 are close to normal distribution. Rsk has positive values, leading to an asymmetrical profile, shifted to the right, indicating a sharp profile of a less wear resistant surface. A normal distribution of profile values results in zero skewness. Rku has values less than 3. A profile with flattened peaks and valleys has smaller Rku values. Amplitude distribution curve is a normal profile for Rku equal to 3, when there are a maximum number of points in the profile around the average line. 4. Conclusions The curves shown in Figure 1 reveal the dependence of roughness parameters Ra and Rt as a function of nose radius r ε. So, if the nose radius increases, the values of roughness parameters decrease, indicating an improvement in surface quality, as indicated by experimental results in Table 1. This can be explained by the changing conditions of plastic deformation in chip formation. 168 The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No. 38
7 By studying the bearing area ratio and the Abbott-Firestone curve, we notice that as the roughness decreases, the lift (bearing area ratio) increases. If the nose radius increases, to get the same rate of lift, we need a cutting depth of the surface becoming less, as indicated by Table. Therefore, improving the quality of the surfaces, turning them with cutting tools with larger nose radii, lead to increased bearing surface, as shown by Figures 7, 8, 9 and 1. Regarding the statistical distribution of depths, presented in Figures 7, 8, 9 and 1, we can conclude the following: Rsk has positive values, leading to an asymmetrical profile, shifted to the right, indicating a sharp profile of a less wear resistant surface. Bearing surface should have negative skew. Rku has values between and 3, the amplitude distribution curve profile having no significant deviations from normal distribution. 5. References [1] B. Murzec, F. Muz, Integral model of selection of optimal cutting conditions from different databases of tool makers. Journal of Materials Processing Technology, vol. 133, 1-,3, pg [] S. M. Darwish, The impact of tool material and cutting parameters on surface roughness of a nickel- base superalloy. Materials and manufacturing Processes Vol. 1, No. 6, 1997, pg [3] E. J. Abbot, F.A. Firestone Specifying surface quality Engineering Mc. Graw Hill Company, New York, 1968 [4] E.C. Teague, F.E. Scire, S.M. Baker & S.W. Jensen, 3-Dimensional stylus profilometry, Wear vol. 83, 198 [5] E.S. Gadelmavla, M.M. Koura, T.M.A. Maksoud, I.M. Elewa & H.H. Soliman, Roughness parameters,, Journal of Materials Processing Technology, Vol. 13, [6] Gh.Gheorghe, Tehnica măsurării inteligente, Ed. CEFIN, Bucureşti 4 [7] E. Diacenko, M.O. Iacobson Calitatea suprafeţelor la prelucrarea metalelor prin aşchiere (translation from Russian), Ed. Tehnică, Bucureşti, 1954 [8] G. Boothroyd, Fundamentals of Metal Machining and Machine Tools, Dekker, New York, 1989 [9] Şt. Enache, a qualité des surfaces métaliques, Ed. Tehnică, Bucureşti, 1994 [1] Capello E., Residual stresses in turning; Part I: Influence of processes parameters, Journal of Materials Processing Technology, 4 The Romanian Review Precision Mechanics, Optics & Mechatronics, 1 (), No
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