Estimation of Material Removal by Profilometer Measurements in Mass Finishing

Abstract:

This paper presents a new procedure to estimate the material removal (MR) in such conditions or operations where small amount of material or wear occur. The monitoring of material removal is essential to understand the machining mechanisms of several processes such as super finishing ones. For example the study of some mass finishing (MF) operations, i. e. the barrel finishing (BF) and the spindle finishing (SF), have been always limited by the difficulty to measure the local surface modification. Thus there is no knowledge about the relationship between process parameters and obtainable surface quality. The procedure is based on profilometer measurements typically used to characterized local surface morphology. An algorithm automatically finds the most representative peak of the profile. The comparison between the Abbot-Firestone curves, related to peaks achieved in different condition, permits to measure the volume of material removed by the operation. This method overcomes the well-known problem to repositioning the instrument in the same place when the part is moved from machining process to measurement one. In the case of BF, experimental demonstrated the reliability of this methodology to provide the evolution of material removed as a function of working time. Moreover the graphical plot of the representative peak at different times gave important information about machining mechanism. In particular it allowed to verify assumptions regarding the plastic deformation and the peak cutting which takes place.

• Periodical: Key Engineering Materials (Volumes 611-612)
• Pages: 615-622
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.611-612.615
• Online since: May 2014
• Authors: Luana Bottini*, Alberto Boschetto, Francesco Veniali
• Keywords: Barrel Finishing , Mass Finishing, Micro Material Removal, Spindle Finishing, Surface Morphology

References

[1] E.H. Tulinski, Mass finishing, in: ASM, Metals Handbook vol. 5. Surface Engineering, 9th edn., ASM International, Materials Park, 1994, pp.261-277.

[2] E.J. Abbot, F.A. Firestone, Specifying surface quality, Mech. Eng. 55 (1933) 569.

[3] ISO 13565/3Geometrical product specifications (GPS) – Surface texture: Profile method; Surfaces having stratified functional properties - Part 3: Height characterization using the material probability curve, (1998), Technical report.

DOI: 10.3403/02108322u

[4] I.B. Corral, J.V. Calvet, M.C. Salcedo, Use of roughness probability parameters to quantify the material removed in plateau honing, Int. J. Mach. Tool Manuf. 50 (2010) 621-629.

DOI: 10.1016/j.ijmachtools.2010.02.007

[5] M. Bigerelle, A. Iost, A numerical method to calculate the Abbott parameters: A wear application, Tribol. Int. 40 (2007) 1319-1334.

DOI: 10.1016/j.triboint.2006.12.007

[6] R. Kumar, S. Kumar, B. Prakash, A. Sethuramiah, Assessment of engine liner wear from bearing area curves, Wear 239 (2000) 282-286.

DOI: 10.1016/s0043-1648(00)00331-8

[7] A. Boschetto, L. Bottini, F. Veniali, Microremoval modeling of surface roughness in barrel finishing, Int. J. Adv. Manuf. Technol. 69( 9-12) (2013) 2343-2354.

DOI: 10.1007/s00170-013-5186-4

[8] H. Henein, J.K. Brimacombe, A.P. Watkinson, The modelling of transverse solids motion in rotary kilns, Metall. Trans. B 14B (1983) 207-220.

DOI: 10.1007/bf02661017

[9] J. Mellmann, The transverse motion of solids in rotating cylinders - Forms of motion and transition behavior, Powder. Technol. 118 (2001) 251-270.

DOI: 10.1016/s0032-5910(00)00402-2

[10] A.A. Boateng, Boundary layer modeling of granular flow in the transverse plane of a partially filled rotating cylinder. Int. J. Multiph. Flow. 24(3) (1998) 499-521.

DOI: 10.1016/s0301-9322(97)00065-7

[11] A. Boschetto, F. Veniali, Workpiece and media tracking in barrel finishing, Int. J. Mach. Mach. Mater. 6(3–4) (2009) 305-321.

DOI: 10.1504/ijmmm.2009.027330

[12] D. A. Davidson, Mass finishing processes, Met. Finish. 99(1)(2001) 110-124.

[13] K. R. Olsen, Choosing the right finishing equipment: Combining customer input and vendor analysis leads to trouble-free production of metal parts, Met. Finish. 104(5) (2006) 19-23.

[14] A. Boschetto, L. Bottini, F. Monarca, F. Veniali, Barrel finishing of FDM parts, in: Enhancing the Science of Manufacturing proceedings of the XI A.I. Te.M. Conference San Benedetto del Tronto, 2013, pp.29-40.

[15] T. Wohlers, Wohlers Report 2012: Executive Summary, Wohlers Associates Inc., Fort Collins, (2012).

[16] N. Hopkinson, R. Hague, P. Dickens, Rapid Manufacturing An Industrial Revolution for the Digital Age, John Wiley & Sons, Chichester, (2005).

DOI: 10.1002/0470033991

[17] K.C. Cooper, Rapid Prototyping Technology. Selection and Applications, Marcel Drekker, Inc., New York, (2001).

[18] A. Boschetto, V. Giordano, F. Veniali, 3D roughness profile model in fused deposition modelling, Rapid Prototyp. J. 19(4) (2013) 240-252.

DOI: 10.1108/13552541311323254

[19] K. Thrimurthulu, P.M. Pandey, N.V. Reddy, Optimum part deposition orientation in fused deposition modeling, Inter. J. Mach. Tools Manuf. 44(6) 585-594.

DOI: 10.1016/j.ijmachtools.2003.12.004

[20] A. Boschetto, V. Giordano, F. Veniali, Modelling micro geometrical profile in fused deposition process, Int. J. Adv. Manuf. Technol. 61(9-12) (2011) 945-956.

DOI: 10.1007/s00170-011-3744-1

[21] C. K Chua, K. F Leong, C.S. Lim, Rapid prototyping: principles and applications, N.J. World Scientific, River Edge, (2010).

[22] P. M Pandey, N.V. Reddy, S.G. Dhande, Improvement of surface finish by staircase machining in fused deposition modelling, Int. J. Mater. Process. Technol. 1(1-3)(2003) 323-331.

DOI: 10.1016/s0924-0136(02)00953-6

[23] K.F. Leong, C.K. Chua, G.S. Chua, C.H. Tan, Abrasive Jet Deburring of Jewellery Models Built by Stereolithography Apparatus, Int. J. Mater. Process. Technol. 83(1-3)(1998) 36-47.

DOI: 10.1016/s0924-0136(98)00041-7

[24] L.M. Galantucci, F. Lavecchia, G. Percoco, Quantitative analysis of a chemical treatment to reduce roughness of parts fabricated using fused deposition modeling, CIRP Annals - Manufacturing Technology 59(1)(2010) 247-250.

DOI: 10.1016/j.cirp.2010.03.074

[25] D. J. Whitehouse, Handbook Of Surface And Nanometrology, CRC Press, New York, (2011).

[26] A. Boschetto, M. Bordoni, Thickening of surfaces for direct additive manufacturing fabrication, Rapid Prototyp. J. 18(4)(2012) 308-318.

DOI: 10.1108/13552541211231734

[27] ISO/DTS 16610-22 Geometrical Product Specifications (GPS) - Filtration - Linear profile filters: Spline filters, International Organization for Standardization (ISO), Geneva, (2006).

DOI: 10.3403/30429462u