6th International DAAAM Baltic ConferenceINDUSTRIAL ENGINEERING24-26 April 2008, Tallinn, Estonia

3D SURFACE ROUGHNESS PREDICTION TECHNIQUE IN END-MILLING

USING REGRESSION ANALYSIS

Kromanis, A.; Krizbergs, J.Abstract:

Purpose of the study is todevelop a technique to predict a surfaceroughness of part to be machined according to technological parameters.Such technique could be achieved bymaking mathematical model of machining. In this study as machining process amilling process is chosen, especially end-milling. Additionally to the study, one of the key factors, which differ from similar studies, is that as surface parameters the3D surface parameters are used. In thisstudy all the surface parameters areexpressed as 3D parameters. 3D surface parameters give more precise picture of the surface; therefore it is possible more precisely to evaluate the surface parameters according to technological parameters. In result of the study, themathematical model of end-milling isachieved and qualitative analysis ismaintained. Achieved model could helptechnologists to understand morecompletely the process of forming surfaceroughness.

Key words: 3D surface roughness; prediction; milling; regression.

1. INTRODUCTION

The quality of surface plays a veryimportant role in functionality of produced part. Therefore, it is necessary to developmethods, which can be used for the prediction of the surface roughnessaccording to technological parameters.There is known some surface roughnessmodels, mainly based on tools geometrical properties and basic technological parameters, mainly feed (f). Theses modelsare not so accurate for surface roughness prediction because they do not count manyother very important technological parameters. One of the means to build amore precise prediction model is to useregression analysis. In this study regressionanalysis is used to predict the surfaceroughness according to technological parameters in end milling. Experiment isconducted to acquire necessary data andregression analysis is used to reach thecredible surface roughness predictionmodel. According to this modelmanufacturing engineers could set cuttingmachines without any long-term adjusting.Material and time economy could bereached and also quality maintained.Further to describe the machined surface3D parameters are introduced. In this paper a 3D surface roughness parameter like Sa(average absolute deviation of the surface)is used. 3D surface roughness parametersgive more precise picture of the surface, because it shows the real environment of the surface.

2. MATERIAL PROCESSING USINGEND MILL – SEQUENCE OFEXPERIMENT

Aim of the experiment is to findrelationships between surface roughness(Average absolute deviation of the surface – Sa) of machined workpiece and usedtechnological parameters (cutting speed – v; feed – f; cutting depth – a). Workpiecewas machined by using end mill in predetermined cutting conditions. After machining a workpiece surface is measuredand 3D surface roughness values are

obtained. The next step is to processmathematical statistic analysis, after whichit is possible to evaluate the influence of technological parameters on formingsurface roughness.

2.1 Initial data of the experiment

Machined workpiece material is stainlesssteel (Stainless steel EN 1.4301 – X5CrNi18-10). 12 end-milling cuts aremade on workpiece. Every cut is madewith different technological parameters(See table 2). Machining was made byusing carbide end mill, which diameter is10 mm and it has 4 teeth.Fig. 1. Drawing of machined workpieceSimultaneously with choosing material of workpiece, a table (See table 1) withtechnological parameters was made. Astechnological parameters the following parameters were chosen: v – cutting speed(m/min); s – feed (mm/rev.) and a – cuttingdepth (mm).Table 1. Listing of technological parameters

No. f (mm)a(mm)v(m/min)

1. 0,25 1,5 1902. 0,25 0,5 1903. 0,1 0,5 1904. 0,1 1,5 1905. 0,1 1,5 1206. 0,25 1,5 1207. 0,25 0,5 1208. 0,1 0,5 1209. 0,21 1 21010. 0,13 1 21011. 0,21 1 10012. 0,13 1 100There is known some publications where toexisting parameters, some additional parameters are put, like material of machined workpiece and geometry of end-mill [

]. Machined workpiece material andtool geometry is counted so far as correcttechnological parameters to be chosen. Inreal life material to be machined is chosen by designer neither by technologists nor CNC operator. It means that this parameter is hard to control in process. Toolgeometry could be better controlled as amaterial of workpiece to be machined. Nevertheless, tool geometry can not bechanged during the cutting process. Theonly really changeable parameters in process are cutting speed (v), cutting depth(a) and feed (f). These parameters werechosen to control the cutting process and tomake evaluation of the machinedworkpiece’s 3D surface roughnessaccording to technological parameters.Referring to the Table 2, limits for thetechnological parameters are chosenaccordingly:- cutting speed (v): 120

≤

190 m/min;- feed (f): 0.1

≤

0.25 mm/rev.;- cutting depth (a): 0.5

≤

1.5 mm.Designation of parameter limits isessential, because choosing parametersoutside designated range can result inappropriate results of experiment. Out of this range it is almost impossible to getsatisfied results to analyze the influences of technological parameters to 3D surfaceroughness parameters. Parameters in positions from 9 to 12 are control parameters.

2.2 Mathematical formulation orregression analysis

The main task for regression analysis is toshow relationship between result (3Dsurface roughness) and factors (v, f, a) andto evaluate a function of this relationship:

),,(

a f v f Sa

(1)In the equation (1) Sa is average absolutedeviation of the 3D surface roughness, f is

response function and v, f, a are variablesof milling, and E is error, which isdistributed on Sa average value.Concerning previous equation (1),relationship between the surface roughness(Sa) and technological parameters (v, f, a)can be written into following style:

321

aaa

va f C Sa

⋅⋅⋅=

(2)where C is constant and a

, a

areexponents.To maintain defining of constant andexponents, a mathematical model has to belinearized, using following logarithmictransformation:

vaaa f aC Sa

lnlnlnlnln

321

+++=

(3)Further this equation (3) is simplified (4),for using it in statistical analysis programcalled MiniTab. lnSa is replaced by y, lnC by b

, a

lnf by b

, a

lna by b

and a

lnv by b

3322110

xb xb xbb y

+++=

(4)

2.3 3D surface roughness measurements

When the machining of workpiece isfinished a surface roughness measurementis performed. For measurements Taylor Hobson Form Talysurf Intra 50 profilometer – profilograph was used. Onevery machined groove a 3x3 mmmeasurement field was chosen. Every fieldwas scanned by 15 strokes and every strokeincluded 100 measurement points.Obtained results were processed inTalySurf Intra program. Further themeasured examples were levelled (Fig. 2)to eliminate form defects. Only surfaceroughness data were processed for 3Dsurface roughness measurement.Fig. 2. Representation of 3D surfaceroughness of machined workpiece: on theleft side –surface roughness beforelevelling; on the right side –surfaceroughness after levellingWhen results of 3D surface roughness (Sa)was obtained, then they were written inMiniTab program for processing. Table 4shows the data, which were used for processing in MiniTab.

2.4 Results of experiment

The final data for processing are shown intable 2. Showed Sa values are averagefrom 3 measurement samples.Table 2. Chosen technological parametersand obtained Sa (average absolutedeviation of the surface)

No. f (mm)a(mm)v(m/min)Sa(µm)

1. 0.25 1.5 190 1.372. 0.25 0.5 190 0.6313. 0.1 0.5 190 0.3884. 0.1 1.5 190 0.9885. 0.1 1.5 120 0.6356. 0.25 1.5 120 1.377. 0.25 0.5 120 1.098. 0.1 0.5 120 0.4729. 0.21 1 210 1.0210 0.13 1 210 0.87111. 0.21 1 100 0.80512. 0.13 1 100 0.47As seen form Table 2, measurements in positions 9 to 12 are control measurements(marked in grey). Technological parameters in these positions were takenwith offset. All these data were put intoMiniTab program and following regressionequation was reached: