Influence of Cutting Parameters and Tool Geometry on Topography of Hard Turned Surfaces

Abstract

Three-dimensional topography measurement is a focus area of precision machining because it provides detailed information on the functional behavior of contacting surfaces. The purpose of this study is to analyze how the process parameters and the edge geometry of the cutting insert influence the topographical characteristics of hardened 16MnCr5 steel surfaces and to determine the favorable combinations of technology parameter values based on the analyzed topography parameters (Ssk, Sku, Sz, Sa, Sk, Spk, Svk). A research question is whether the analyzed parameters can be substituted by each other or not. A hard turning experiment was carried out based on a full factorial design of experiments, and the areas of the machined surfaces were scanned and analyzed by analysis of variance, regression analysis (response function), and correlation analysis. It was found that there are strong correlations between the topography parameters that allow the substitution of one with another; the main influencing cutting parameter is the feed rate for both insert types. The contributions of the study are the numerical information with regard to the correlations among the topography parameters, as well as the extent of the influence of cutting parameters.

Evaluation of the Feasibility of the Prediction of the Surface Morphologiesof AWJ-Milled Pockets by Statistical Methods Based on Multiple Roughness Indicators

“…Thoughmany researchers usually characterize surface quality based on the most fundamental 2D or 3D roughness parameters, e.g., Ra, Rz or Sa and Sz, surface profiles are toocomplex to be sufficiently described by only a small numberof such parameters [4,5]. Thus, it is recommended that multiple parameters of the surface roughness of machined surfaces should be studied in order to gain a deep insight intothe implications of machining parameters on surface quality [6]. In some cases, special techniques must beemployed in order to obtain a more accurate estimation of the roughness parameters' values [7], especially online, which is a challenging task [8][9][10].…”