The influence of cutting parameters on micro-topography of frequency features extracted from the machined KH₂PO₄ surfaces

Abstract

Using reasonable cutting parameters of machining process is an effective and convenient means of improving the topography of the machined surfaces. In this study, the methods to find optimised cutting parameters can be obtained by studying the relationship between the cutting parameters and the micro-topography of frequency features in the machined KH2PO4 surfaces. Using the power spectral density and continuous wavelet transform methods, the 2D micro-topographies of frequencies corresponding to different cutting parameters are extracted from the machined KH2PO4 surfaces. The results for the extracted micro-topography are used to analyse the influence of cutting parameters on the spatial frequency feature which consists of the wavelength and amplitude. The middle-frequency feature reflects the variations of depth of cut and spindle speed, and the amplitude of it is directly proportional to depth of cut and spindle speed. The low-frequency feature reflects the variations of the feed rate and decreases to a smaller value when the feed rate increases. The high-frequency feature is mainly affected by the material properties and the vibrations that occur during processing. Comparing the micro-topography of frequencies under different cutting parameters, the depth of cut (3 μm), the spindle speed (400 r/min) and the feed rate (8 μm/r) are the optimised cutting parameters for the machine tools used in this article. In the process of reconstructing the arbitrary frequency topography, the continuous wavelet transform method can compensate for the deficiencies of the power spectral density method for extracting frequencies.

Surface roughness and chip morphology of wood-plastic composites manufactured via high-speed milling

“…According to Gurau and Ayrilmis (2019), the surface roughness of WPCs is affected by the composition of the raw materials used for manufacturing. Pang et al (2020) believed that cutting parameters are the main factors determining the surface morphology of the workpiece. When processing oak wood, Ugulino and Hernandez (2017) found that the feed speed was the most influential cutting parameter affecting the surface roughness, and the surface roughness increased with an increase in the feed speed.…”

Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

“…The relationship between the topological matrix of grinding wheel surface topography and the depth of cut is the basis for judgment. The active cutting edge can be determined by using equation (15), as follows:…”

“…13,14 In grinding, the final surface roughness of the workpiece is formed by the interference of the movement of multiple abrasives and is affected by the grinding parameters. 15 The reciprocation of the ironing of abrasives in TUAG reduces the height of the residual material on the processed surface. Recent studies have found that the surface roughness decreases under ultrasonic grinding conditions, but the effects of ultrasonic vibration are not apparent with uprated process parameters.…”

Fractal Analysis on Machined Surface Morphologies of Soft-Brittle KDP Crystals Processed by Micro Ball-End Milling

“…To bridge this gap, a great number of efforts have been made to evaluate machined surface morphologies during the past decades. For instance, the power spectrum density (PSD) [28,29] has been used to extract the frequency information from machined surfaces, while the continuous wavelet method [30] has been employed to analyze the dynamic evolution process of the dominated frequency with the change of machining distance. These methods are all based on the Fast Fourier Transform analysis of the surface contour data, which are similarly affected by the measurement conditions.…”