Mathematical modeling of surface roughness in polystyrene foam machining

Gote, Gopal; Kamble, Pushkar; Hodgir, Rajendra; Mittal, Yash Gopal; Karunakaran, K. P.

doi:10.1007/s00170-022-09229-6

Cited by 1 publication

(2 citation statements)

References 21 publications

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“…The two mechanisms observed were through-bead cutting and bead removal. Very recently, Gote, Kamble, Hodgir, Mittal and Karunakaran [14] proposed that when the tool contacts the bead during EPS machining, if the strength between beads is higher than the intra-bead strength, the bead is first deformed into an oval shape, then cut throughout, and finally the foam recovers its shape after the tool leaves. However, if the inter-bead strength is lower, the whole bead may be removed after it is initially compressed.…”

Section: Resultsmentioning

confidence: 99%

“…Only very recently a paper has proposed a model to correlate surface roughness with cutting mechanisms during machining of polystyrene foams used in foundries. However, the only topographical parameter proposed in their approach was the 2D parameter root square mean (rms) roughness Ra [14]. In another work, the machining step of segmented object manufacturing (SOM) was optimized in terms of cutting speed, linear feed, step-over, and step-down.…”

Section: Introductionmentioning

confidence: 99%

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Surface metrology as a tool in surfboard manufacturing to assess machinability of expanded polystyrene blanks via CNC milling

Mielke¹,

Costa²,

Amado³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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Surfboards have been manually made for many years, thus becoming unique pieces, but with numerous physical and ergonomic risks for the health of the operator (shaper). With the recent technological advance, surfboard manufacturing shifted towards CNC milling, improving quality and reproducibility, as well as reducing the risks to the health of the operator. However, even though most of the current surfboards are manufactured industrially, the use of rigorous surface metrology is scarce to control the surface finish of CNC-milled expanded polystyrene (EPS) blanks. The present study aimed to evaluate the surface finish of EPS blanks machined by a CNC milling machine with a diamond disc tool, designed for surfboard manufacturing. Four EPS blanks of different brands and densities were characterized, machined at two feed rates: (a) 10 m/min and (b) 5 m/min, and the quality of the surface finish was evaluated. Scanning electron microscopy as well as a confocal laser scanning microscope were used to evaluate the surface morphology. A range of topographical parameters was proposed and assessed. The structural characteristics of the EPS blanks demonstrated that the machined material is easily mouldable, not causing damage to the tool, thus requiring little maintenance for tool periodic replacement. The use of confocal microscopy proved to be efficient for the evaluation of the quality of the surface finish of EPS blanks and a set of topographical parameters was chosen. The higher density blanks showed better surface finish after machining at the feed rate of 5 m/min, while the lower density blank had a better surface finish when machined at the feed rate of 10 m/min. In particular the parameters Ssk and Sku could detect problems in the surface morphology resulting from machining EPS blanks.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%