University of Kragujevac,

Serbian Tribology Society

Faculty of Engineering

SERBIATRIB ‘17
15th International Conference on Tribology
17 – 19 May 2017, Kragujevac, Serbia

PROCEEDINGS
EDITOR: Slobodan Mitrović
15th International Conference on Tribology – SERBIATRIB ‘17 
PROCEEDINGS 
 
 
ISBN: 978‐86‐6335‐041‐0 
 
 
 
 
Editor:  Slobodan Mitrović
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University of Kragujevac, Faculty of Engineering 
   
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 SERBIATRIB ‘17
15th International Conference on
Serbian Tribology Tribology Faculty of Engineering
Society University of Kragujevac
Kragujevac, Serbia, 17 – 19 May 2017

CORRELATION OF SURFACE ROUGHNESS PARAMETERS WITH

OPERATIONAL VARIABLES IN TURNING OF A NEW ALUMINUM MATRIX
STEEL PARTICULATE COMPOSITE: A MULTI-PARAMETER ANALYSIS
Nikolaos M. VAXEVANIDIS1*, Athanasios G. MOURLAS2, Nikolaos A. FOUNTAS1,
Georgios V. SERETIS3, Christopher G. PROVATIDIS3, Pandora P. PSYLLAKI2, Dimitrios E. MANOLAKOS3
1
Department of Mechanical Engineering, School of Pedagogical and Technological Education
(ASPETE), Athens, Greece
2
Piraeus University of Applied Sciences, Egaleo, Greece
3
School of Mechanical Engineering, National Technical University of Athens, Greece
*Corresponding author: vaxev@aspete.gr

Abstract: Present study concerns with a multi-parameter experimental and statistical analysis of surface
texture in turning of stainless steel flakes reinforced cast aluminum matrix particulate composite (AMPC).
Spindle speed, n (rpm) and feed rate, f (mm/rev) were assigned to an L9 Taguchi orthogonal array as
independent variables whilst depth of cut was kept constant. The response/output (performance
characteristic) was an increased number of surface roughness parameters including amplitude, hybrid,
statistical and fractal ones. The multi-parameter analysis of surface finish was selected since the evaluation
of the roughness with one or two only parameter is ambiguous. The correlation of these parameters with
the machining conditions was investigated. Then, statistical analysis and was applied to quantitatively allow
exploration of the effect which each machining input yields on roughness outputs. Regression equations
were constructed then, in order to develop prediction models with the possible lower estimation error.

Keywords: surface roughness, aluminum matrix particulate composite; stainless steel flakes; turning; multi-
parameter analysis, regression equations.

In Memoriam Prof. B. Ivković (1931-2016) and Prof. G.P. Petropoulos (1959-2010)

1. INTRODUCTION components [1, 2]. Turning is the primary

Metal cutting operations are widespread in
manufacturing industry and the prediction
and/or the control of relevant machinability
parameters always attracts interest. A basic
machinability parameter is the surface texture,
as it is closely associated with the quality,
reliability and functional performance of
15th International Conference on Tribology – Serbiatrib ‘17
operation in metalworking industry for
producing axisymmetric components. These
components, typically, possesses critical
features that require specific surface finish and
the best possible functional behaviour. Due to
inadequate knowledge of the complexity of
the process and factors affecting the surface
integrity in turning operation [3], an improper
343
decision may cause high production costs and
low machining quality. The proper selection of
cutting tools and process parameters for
achieving high cutting performance in a
turning operation is a critical task [2-4].
The various manufacturing processes
applied in industry produce the desired shapes
of the components within prescribed
dimensional tolerances and surface quality
requirements. Therefore, any proposed
description of a technological surface should
take into account the features of the profile
imparted by the machining process performed.
This is a crucial point because the process can
be controlled through surface texture
recognition which also can be used to
generate suitable profiles for tribological
functioning [5].
In the common industrial practice surface
roughness is evaluated by profile amplitude
parameters such as Ra, Rt etc., which, however,
do not provide information on the shape of
the profile. Characteristics like inclination and
curvature of the surface roughness asperities,
“emptiness” or “fullness” of the profile,
distribution of the profile material at various
heights are included in the profile shape. The
essential tribological aspects (e.g. friction,
wear, conditions of lubrication) are highly
dependent on profile shape [5, 6]. In this
regard, the characterization of machined
surface shapes is necessary; this can be
achieved only, through multi- parameter
statistical analysis [6-10].
The present study concerns with a multi-
parameter experimental and statistical
analysis of surface texture in turning of
stainless steel flakes reinforced cast aluminum
matrix particulate composite (AMPC). Spindle
speed, n (rpm) and feed rate, f (mm/rev) were
assigned to an L9 Taguchi orthogonal array as
independent variables whilst depth of cut was
kept constant. The response/output
(performance characteristic) was an increased
number of surface roughness parameters
including amplitude, hybrid, statistical and
fractal ones. The multi-parameter analysis of
surface finish was selected since the
evaluation of the roughness with one or two
344
only parameter is ambiguous. The correlation
of these parameters with the machining
conditions was investigated. Statistical analysis
was applied to quantitatively allow exploration
of the effect which each machining input
yields on roughness outputs. Regression
equations were constructed then, in order to
identify prediction models with the possible
lower estimation error.
It should be noted that for the study of the
influence of operational parameters on
machining performance during turning,
besides statistical methods, soft computing
techniques such as artificial neural networks
and genetic algorithms can be applied see for
example Refs [3, 11, 12] and [13] respectively.
2. SURFACE ROUGHNESS PARAMETERS
Surface roughness evaluation is very
important for many fundamental problems
such as friction, contact deformation, heat and
electric current conduction, tightness of
contact joints and positional accuracy. For this
reason surface roughness has been the subject
of experimental and theoretical investigations
for many decades. The real surface geometry
is so complicated that a finite number of
parameters cannot provide a full description. If
the number of parameters used is increased, a
more accurate description can be obtained.
This is the main reason for introducing new
parameters for surface evaluation [5, 7, 10].
More than one hundred parameters have
been proposed in the literature, owing to the
fact that a real profile shape is usually very
complicated, and the functional requirements
for the components are very high in today’s
industry [5]. Since the estimation of the
roughness performed with one parameter is
ambiguous, the multi-parameter estimation of
roughness is recommended [2, 5, 14]. Surface
roughness parameters are normally
categorized into three groups according to its
functionality. These groups are defined as
amplitude parameters, spacing parameters,
and hybrid parameters [7]. The surface
roughness parameters under study were:
15th International Conference on Tribology – Serbiatrib ‘17
• the arithmetic average, Ra; Cutting experiments were performed on a
• the maximum height of the profile; Rt or Mondiale Gallic® 14 conventional lathe
Rmax; equipped with a NC positioning unit. The ISO 6
• the ten point height, Rz; L1616 P20-grade brazed carbide cutting tool
• the root mean square (RMS) roughness, Rq; (PVD TiN coated) from Sandvic Coromant®
• the skewness of the amplitude distribution, with 0.8 mm tip radius for continuous turning
Rsk; was employed. Coolant was not used during
• the kurtosis of the amplitude distribution, the tests.
Rku; Spindle speed and feed rate were treated
• the bearing or Abbott curve parameter at 1 as the independent machining parameters
μm under the highest peak, Rtp; whilst a number of roughness parameters (see
• the fractal dimension, D. section 2) were treated as the responses on an
L9 Taguchi orthogonal array design. The depth
3. EXPERIMENTAL of cut was kept constant for all turning passes
at a=1.0 mm.
In this study for the fabrication of The surface roughness analysis was
composite rod, an Al-Mn alloy containing Mg performed using a Rank Taylor-Hobson®
was used as matrix material. The purity of the Surtronic 3 profilometer equipped with the
matrix alloy was 96.6 %. Stainless steel 316L Talyprof® software. The cut-off length was
flakes (SSF) were used as reinforcing fillers. Al- selected at 0.8 mm whilst three
Mn/SSF composite rods with SSF content measurements were conducted on every pass
equal to 0.25% wt were produced. The at the longitudinal direction. Measured
fabrication of the aluminum/stainless steel average values for all surface roughness
flakes composite by casting was reported in parameters under study together with the
[15]; therefore it is not presented here, see corresponding cutting variables are tabulated
also Ref. [16] for additional details on the in Table 1.
fabrication technique.
Table 1. Measured values for surface roughness parameters.
Exp. n f Ra Rt Rz Rq Rsk Rku RTp D
(rpm) (mm/rev) (μm) (μm) (μm) (μm) (%)
1 200 0.05 1.86 12.88 11.27 02.30 00.11 02.92 01.86 1.22
2 200 0.27 8.43 46.53 41.80 10.33 00.52 02.79 00.67 1.10
3 200 0.60 8.57 44.10 38.53 10.06 00.27 02.45 00.60 1.07
4 800 0.05 0.65 04.85 04.35 00.83 -00.21 03.10 07.71 1.36
5 800 0.27 8.20 45.67 41.03 10.05 00.04 02.48 00.63 1.07
6 800 0.60 7.77 47.00 39.80 09.65 00.54 03.67 00.63 1.01
7 1600 0.05 0.88 06.54 05.42 01.09 -00.19 02.84 03.80 1.37
8 1600 0.27 7.96 50.13 39.23 09.63 00.38 03.33 00.33 1.12
9 1600 0.60 8.49 51.50 43.30 10.51 00.44 03.33 00.56 1.10

4. RESULTS AND DISCUSSION spindle speed levels, therefore it is deemed as

4.1. Experimental observations
The variation of Ra, Rt and Rz values with
feed rate for all three spindle speeds applied is
presented in Figures 1, 2 and 3 respectively.
When turning under the lowest level for feed
rate (i.e. f=0.05 mm/rev), Ra is kept low for all
15th International Conference on Tribology – Serbiatrib ‘17
the most influential parameter affecting Ra.
Lowest value for Ra was obtained for spindle
speed equal to 800 rpm with 0.05 mm/rev
feed rate. For the same feed, Ra slightly
increases when spindle reaches 1600 rpm.
Experimental observations for Rt and Rz as well
as for Rq are quite similar to those for Ra, as it
is expected. Moreover, variation patterns
345
presented in Figures 1 and 2 are quite
different from the ones observed in turning of
pure Al-Mn alloy (matrix material) under the
same experimental conditions; see Ref. [17].
Note, that arithmetic average roughness
(Ra) is by far the most commonly used
parameter in surface finish measurement and
for general quality control. Despite its inherent
limitations, it is easy to measure and offers a
good overall description of the height
characteristics of a surface profile. On the
other hand, Rt is very sensitive to the high
peaks or deep scratches. Rq (RMS) is more
sensitive to peaks and valleys than Ra, but less
robust whilst Rz is the most versatile process
control parameter, very sensitive to process
changes and relatively robust.
Figure 1. Variation of Ra in relation to operational
parameters
Figure 2. Variation of Rt in relation to operational
parameters
Skewness parameter (Rsk) is typically used
to measure the symmetry of the profile about
the mean line and is sensitive to deep valleys
or high peaks. A symmetrical height
distribution, i.e. with as many peaks as valleys,
has zero skewness. Profiles with peaks
removed or deep scratches have negative
346
skewness. Profiles with valleys filled in or high
peaks have positive skewness.
Figure 1. Variation of Rz in relation to operational
parameters
The variation of Rsk with feed rate for all
three spindle speeds applied is presented in
Figure 4. Rsk reaches its highest value when
turning the composite rod using a spindle
speed equal to 800 rpm with a feed rate equal
to 0.27 mm/rev.
Figure 4. Variation of Rsk in relation to operational
parameters
Kurtosis (Rku) typically describes the
sharpness of the probability density of the
profile. When Rku < 3 the distribution curve is
said to be platykurtoic and has relatively few
high peaks and low valleys. When Rku>3 the
distribution curve is said to be leptokurtoic
and has relatively many high peaks and low
valleys. The variation of Rku in relation to
operational parameters is presented in Figure
5. Measured values of this parameter are in
the range of around 3 indicating normally
distributed high peaks and low valleys.
Bearing (Abbott) curves and bearing ratio
parameters are useful tools for analyzing
surface morphology in relation to tribological
performance [18]. The Rtp (Abbot) parameter
15th International Conference on Tribology – Serbiatrib ‘17
representing the cross-section of surface
material at 1 μm under the highest peak was
determined for all conditions examined; see
Figure 6. Note that Rtp is used primarily for the
analysis of load carrying surfaces.
Figure 5. Variation of Rku in relation to operational
parameters
Figure 6. Variation of Abbott curve parameter Rtp
vs. operational parameters
Figure 7. Variation of fractal dimension D with
operational parameters
Fractal-based methods for describing
surface texture have attracted great interest
since they can provide information that
conventional surface roughness parameters
cannot [9]. The fractal dimension D was
calculated via the power spectrum method
and it appears rather insensitive to operational
15th International Conference on Tribology – Serbiatrib ‘17
parameters; see Figure 7. Note that fractal
analysis has not been introduced so far in ISO
surface metrology standards; see for example
ISO 4287: 1997, but it is used and calculated
via in-house and commercial software [9].
Moreover, application of fractal analysis to
machined surfaces obtained by tool of defined
geometry, as in the case of turning, is still
open to discussion.
4.2. Statistical analysis
Statistical analysis was performed in order
to examine the effect of spindle speed and
feed rate upon roughness parameters under
examination. The statistical software
MINITAB® 17 was used for conducting the
corresponding analysis and to obtain the
outputs for results interpretation. Main effects
and interactions plots were generated to study
the influence among parameters’ levels and
their combinations respectively, on Ra and Rt
roughness parameters. Figure 8 shows that
average roughness (Ra) is greatly affected by
feed-rate, followed by spindle speed whilst
significant interactions are noticed mainly
between the second and the third level for
spindle referring to the second level for feed-
rate; see Figure 9.
Figure 8. Main effects plot using the data means
for Ra
Similar analysis was performed to interpret
the effect of cutting conditions on maximum
roughness (Rt). Figures 10 and 11 illustrate the
main effects of independent variables and
their interactions. According to these outputs,
Rt is strongly affected by feed-rate which exert
the largest influence against spindle speed
considering the experiment’s preset levels.
347
 More accurate results concerning the
effects of machining parameters on the
responses of Ra and Rt can be obtained by
conducting ANOVA analysis; see for example
Refs [12, 19].

4.3. Prediction models for roughness

parameters

Based on the experimental results

presented above; see also Table 1, several
Figure 9. Interactions plot using the data means for
Ra prediction models of different types can be
formulated. These models typically include: a)
the general linear model for first-order; b) the
least squares approach – second order model
and c) the exponential one [17].
During present investigation full quadratic
models were developed for all roughness
responses; see Table 2 whilst exponential
models were implemented for Ra and Rt; see
Table 3.
Figure 10. Main effects plot using the data means By examining coefficient of determination
2
for Rt (R values in Table2 it is evident that Ra, Rz, Rq,
Rt and D parameters are highly correlated to
their corresponding coefficients and
independent parameter values; whilst the
opposite is revealed for Rsk Rku and RTp. These
parameters remain uncorrelated and their
models cannot be employed.
Exponential models; see Table 3, are
characterized by lower coefficient of
determination (R2); therefore their use for
Figure 11. Interactions plot using the data means prediction is not reccomended.
for Rt
Table 2. Full quadratic regression equations for the prediction of roughness parameters.
Response Regression model R2 (%)
Ra = -0.107-0.0027×n+49.68×f+10-6×n2-57.97×f2+10-2×n×f 99.75
Rt = 0.85-0.014×n+268.5×f+6×10-5×n2-324.7×f2+0.016×n×f 99.54
Rz = 1.57-0.011×n+230.6×f+3×10-5×n2-279.1×f2 +0.013×n×f 99.62
Rq = -0.12-3×10-3 ×n+59.8×f+10-5×n2-70.6×f2+2×10-3 ×n×f 99.78
Rsk = 0.114-7×10-4×n+2.3×f-2.8×f2+6×10-3×n×f 80.46
Rku = 2.8+6×10-4×n-2.1×f+2.3×f2+10-3×n×f 49.32
RTp = 32.7+0.074×n-267×f-4×10-4×n2+326×f2-0.017×n×f 76.55
D = 1.33+4×10-4×n-1.41×f+0.01×n2+1.62×f2-12×10-3×n×f 92.62
Table 3. Exponential equations for the prediction of Ra and Rt roughness parameters.
Response Regression model R2 (%)
Ra 4.7×104×n-18.17×f15.82 75.00
Rt 1.12×104×n-13.04×f11.47 62.80

348 15th International Conference on Tribology – Serbiatrib ‘17

5. CONCLUSIONS
A multi-parameter experimental and
statistical analysis of surface texture in turning
of a new aluminum matrix steel particulate
composite was presented. Spindle speed (n)
and feed rate (f) were treated as the
independent machining parameters whilst
roughness parameters including Ra, Rt, Rz, Rq,
Rsk Rku, RTp and D were treated as the
responses on an L9 Taguchi orthogonal array
design.
Variation patterns of roughness parameters
for the composite rod tested are in same cases
different from the ones observed in turning of
pure Al-Mn alloy (matrix material) under the
same experimental conditions
The correlation of responses with cutting
variables was successfully achieved for Ra, Rz,
Rq, Rt and D parameters by using full quadratic
regression equations. On the contrary, it was
shown that Rsk, Rku as well as RTp remain
uncorrelated according to experimental results.
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