Simulation Approach for Surface Roughness Interval Prediction in Finish Turning

Existing simulation models used in predicting the surface roughness of a workpiece in finish turning are based on an ideal circular cutting tool nose profile. This leads to a single predicted roughness value for a given set of input parameters. In this paper, a simulation approach that considers the random tool nose profile micro-deviations as well as the tool chatter vibration to predict a roughness interval is proposed. The nose profiles used in the simulation were extracted from images of the real cutting tool inserts using sub-pixel edge location. The chatter vibration signal was reconstructed from the measured signals and was superimposed onto the extracted nose profile. The roughness data were computed from 24 simulated workpiece surface profiles and used to determine the 95 % roughness prediction interval. Comparison with the experimental results showed that 100 %, 96 % and 96 % of the Rt, Ra and Rq roughness values obtained experimentally fell within the predicted roughness intervals. (Received in March 2015, accepted in September 2015. This paper was with the authors 1 month for 1 revision.)