Identification of Surface Generation Mechanisms Based on Process Feed-Back and Decomposition of Feed Marks

Abstract

This paper proposes a novel integrated approach to the prediction of surface generation mechanisms which takes into account both cutting process outputs and distortions of the individual feed marks in comparison to an ideal kinematical model. For this task, the recorded surface roughness profile was decomposed using special algorithms. The mechanisms of real surface generation considered include the plastic side flow and spring back effects, the cutting edge sharpness and its wear, and dynamic interactions between the tool and the workpiece. The computation procedure was verified for different workpiece materials in conjunction with uncoated and coated, sharp and worn, tools.

Automatic identification of feed marks in machined surface roughness profiles by correlating random variations

“…The emergence of such evidence from a profile lends a physically meaningful basis for the identification of individual tool marks. It is furthermore suggested that mechanisms investigated by Grzesik and Brol such as plastic flow, friction, and elastic recovery [3] may obfuscate the ends of tool marks in visual inspection, but not affect CDI.…”

“…Firstly, theorists interested in modeling surface generation from machining may benefit from statistically validated identification of tool marks, and visual identification may be difficult in some cases. Grzesik and Brol decomposed feed marks to study the mechanisms of their generation [3]. Secondly, the identification of tool marks may be useful in quality control; Carroll et al explain that there is value in automatically distinguishing defects from the rest of a machined surface [2].…”

“…Grzesik and Brol identified marks by fitting parabolas to profiles [3]. However, fitting in such a manner requires the selection of an assumed tool mark shape, which limits the ability to automate the analysis.…”

Application of Magnetic Sensor for Magnetic Profile (1D) and Surface (2D) Measurement of Automotive Wheels

“…The first one is the measurement of the magnetic profile along tread’s circumference. This is so-called (1D) measurement [ 21 ], and the result is a circumferential profile of vector B . The B vector can consist of many projections of B in dependence of sensor design.…”

Surface integrity generated by oblique machining of steel and iron parts

“…Methodology for determining the cumulative effects of several factors was recently proposed by Grzesik and Brol (2011). As the first attempt, the improved predicted model for Ra parameter in oblique turning with straight cutting edge, considering both the minimum undeformed chip thickness (h min ) and relative displacements of the tool traces (cutting vibration) within the surface profile (D( )), can be expressed in the form of Eq.…”