This paper presents a novel approach to surface roughness parameter estimation during finish cylindrical end milling. The proposed model includes the influence of cutting parameters, the tool's static run out and dynamic phenomena related to instantaneous tool deflections. The modeling procedure consists of two parts. In the first stage, tool working part instantaneous displacements are estimated using an analytical model which considers tool dynamic deflections and static errors of the machinetool-holder-tool system. The obtained height of the tool's displacement envelope is then applied in the second stage to the calculation of surface roughness parameters. These calculations assume that in the cylindrical milling process, two different mechanisms of surface profile formation exist. Which mechanism is present is dependent on the feed per tooth and the maximum height of the tool's displacement envelope. The developed model is validated during cylindrical milling of hardened hot-work tool steel 55NiCrMoV6 using a stylus profiler and scanning laser vibrometer over a range of cutting parameters. The surface roughness values predicted by the developed model are in good agreement with measured values. It is shown that the application of a model which includes only the effect of static displacements gives an inferior estimation of surface roughness compared to the model incorporating dynamic tool deflections.
SummaryIn this paper the surfaces of butt welded joints in steel tubes were analyzed using an optical 3D measurement system to determine the morphology and topographic parameters. It was established that pollution of the argon shield gas with oxygen did not influence the width of the heat-affected zone. However, the composition of the shield gas significantly influenced the surface asymmetry, Ssk, and its inclination Sku. The measurement of these parameters enabled the selection of a higher quality surface, which was visually proven by the reduction in discoloration of the surface of the weld joint. High quality surfaces eliminate a potential habitat for bacteria and a future source of corrosion as well as providing less resistance to fluid flow.
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