DANUBE ADRIA ASSOCIATION FOR AUTOMATION & MANUFACTURING

DAAAM INTERNATIONAL VIENNA

PDF OFF-PRINTS
Author(s):
KROMANIS, A[rtis] & KRIZBERGS, J[uris]

This Publication has to be referred as:

Kromanis, A. & Krizbergs, J. (2009). Prediction of Surface Roughness in
End-Milling using Fuzzy Logic and its Comparison to Regression Analysis
(2009). 0803-0805, Annals of DAAAM for 2009 & Proceedings of the 20th
International DAAAM Symposium, ISBN 978-3-901509-70-4, ISSN 1726-
9679, pp 402, Editor B[ranko] Katalinic, Published by DAAAM
International, Vienna, Austria 2009

www.daaam.com

DAAAM INTERNATIONAL VIENNA – VIENNA UNIVERSITY OF TECHNOLOGY

Austrian Society of Engineers and Architects – ÖIAV 1848
 0803

Annals of DA
AAAM for 2009 & Proceedings
P of the 20th
2 International DAAAM
D Symposium
m, Volume 20, No. 1, ISSN 1726-96799
ISBN 978-3-9001509-70-4, Editor B.
B Katalinic, Publishhed by DAAAM Innternational, Viennaa, Austria, EU, 20099
Make Harm mony Between Technnology and Nature, and Your Mind willl Fly Free as a Birdd
Annals of DA
AAAM Internationall

PREDIC
CTION OF SURFACEE ROUGH
HNESS IN END-MILL
E LING USIN
NG FUZZY
Y LOGIC
AN
ND ITS CO
OMPARISO
ON TO REGRESSIONN ANALYSIS

KR
ROMANIS, A[rtis] & KRIZ
ZBERGS, J[u
uris]

Abstract: Nowwadays, a use of highly autoomated machinnes in 2. DESIGN

D OF EXPERIMEN
E NT
manufacturingg requires relliable models for predictioon of
surface roughness. This studdy focuses on developing
d empiirical Machined
M workkpiece materiall was stainless steel (Stainlesss
prediction moodels using reggression analyssis and fuzzy logic.
l steell EN 1.4301 – X5CrNi18-100). 12 end-milling cuts weree
These models later can be used
u to predictt surface roughhness madde as part of it is shown in Fiig. 1. Every cutt (10mm wide))
according to technological parameters.
p Thhe values of suurface was made with diffferent technoloogical parameteers as shown inn
roughness preedicted by thesse models are then
t comparedd with tablee 1. Machiningg was made byy using carbidee end-mill withh
those from meeasured – repreesenting proceddures for validdation diam
meter 10 mm, annd having 4 teeeth.
and comparisoon of models. In
I addition, 3D surfaces roughhness
parameters innstead of 2D roughness parrameters are used,
giving more precise look at the devellopment of suurface
roughness in end-milling. Research
R showeed that Fuzzy logic
model gives more
m precise prediction
p on surface roughhness.
Further research could be done
d in implementing these models 10 (12x)

in CNC adaptiive control mecchanisms. 23 (11xx)

Key words: ennd-milling, surfa

face, roughness,, fuzzy, regressiion Fig. 1. Sketch of machined
m workpiece showing sllots

1. INTRODU
UCTION As
A technologiical parameters the following data weree
chossen: f – feed (mm/rev.);
( d – depth of cut (mm) and v –
Quality off surface roughnness plays a veery important roole in cuttiing speed (m/mmin) (see Tablee 1). After cond
ducting cuttingg
manufacturingg. It is essenttial to maintaain desired suurface proccess a surface rooughness (Sa – mean surface roughness)
r wass
roughness durring cutting process. It is necessary to estaablish meaasured. It was performed
p on T
Taylor Hobson Form Talysurff
models whichh can be useed to predict surface roughhness Intraa 50 profilogrraph. Obtainedd results weree processed inn
according to used
u technological parameters.. Cutting parammeters TalyySurf Intra sooftware. Fig. 2 shows a viisualization off
meaasured 3D surfacce roughness.
are variables which are nonn-linear, interdeependent or haard to
quantify withh satisfactory precision. Suuch models would w
increase undderstanding about surface roughness
r forrming
process according to various technologicall parameters. ThereT
were attemptss to develop em mpirical modells with such a data
mining techniiques like regreession analysiss and computattional
neural networkks (Feng & Waang, 2002). Reggression analysiis is a
technique for modeling the relationship beetween two or more
variables and is well known from previouss studies (Lou et e al., Fig. 2. 3D surface roughness
r visuaalization
1998). In this study empiricaal models were developed by usingu
two methods: regression analysis
a and fuzzy
f logic. Exact
E
novelty is a use of fuzzy logic to devellop a more prrecise No f d v Sameas Sareg
Safuzzy
prediction moodel. In most reecent years Fuzzzy logic has innvade (mm/rev.) (m mm) (m/min) (µm)
in industry. Fuzzy
F logic iss derived fromm fuzzy set thheory 1 0.25 1.5 190 1.37 1.325 1.392
(Zadeh, 1965)) dealing with reeasoning that iss approximate rather
r 2 0.25 0.5 190 0.631 0.8879 0.600
than preciselyy deduced from classical prediicate logic (Booolean 3 0.1 0.5 190 0.388 0.4419 0.408
Logic). Fuzzyy logic is the saame as “impreccise logic” or a new 4 0.1 1.5 190 0.988 0.8825 1.000
way of expressing probabiility. Despite the advantagees of 5 0.1 1.5 120 0.635 0.7767 0.600
classical Boollean Logic acccuracy it has major drawbacck: it 6 0.25 1.5 120 1.37 1.2267 1.392
cannot reprodduce human thought
t patternns (Inform, 2001). 7 0.25 0.5 120 1.09 0.8821 1.000
That’s where Fuzzy logic dooes its work. Itt allows repressent a 8 0.1 0.5 120 0.472 0.321 0.408
human thoughht (experience and knowledgge) in mathemaatical 9 0.21 1 210 1.02 1.0036 1.000
manner, whichh allows incorpporate the ambiiguous, approxiimate 10 0.13 1 210 0.871 0.7770 0.856
nature of hum man logic intoo computers. This
T human thoought 11 0.21 1 100 0.805 0.8882 0.712
could be thoought of CNC C operator whho manages cuutting 12 0.13 1 100 0.407 0.6616 0.462
regimes to maintain
m desiredd surface rougghness (Tomom mitsu, Tab.. 1. Technological parameters (f; d; v), measuured 3D surfacee
1997). Using this method a fuzzy model was developedd and rougghness (Sameas), 3D surface rouughness calculaated from
compared withh quite commonn regression moodel. regreession model (S
Sareg) and from fuzzy model (S Safuzzy)
0804
3. REGRESSION MODELING
A functional relationship between surface roughness and
the independent variables under investigation is defined by:
Sa = C ⋅ f a1 ⋅ d a2 ⋅ v a3
, (1)
where C – regression constant, Sa – 3D surface roughness (Sa –
mean surface roughness) in μm, f – feed in mm/rev., d – depth
of cut in mm, and v – cutting speed in m/min.
After logarithmic transformation the nonlinear form of
Equation 1 was converted into a linear form, which then was
used to develop regression model. To establish the prediction
model, a software package MiniTab was used to perform the
regression analysis using data of the table 1.
After conducting regression analysis in MiniTab a
following regression model was developed:
Sa = −0,403 + 3,33 f + 0,446d + 0,00140v
. (2)
The next step was evaluation of the model. Experiment data
(technological parameters) were put into the model and surface
roughness parameters (Sareg) were calculated (see Table 1).
4. FUZZY MODELING
Fuzzy modelling was performed in fuzzyTECH software.
First of all, a fuzzy model must be designed, which shows
relationships among input data, operator and output data (see
Fig. 3).
Fig. 3. Fuzzy model
The next step is to define membership functions for all
input and output parameters (see Fig. 4) and to draw a rule
book, which defines relationships between technological
parameters and surface roughness
Fig. 4. Membership functions for depth of cut (d), feed (f),
cutting speed (v) and 3D surface roughness (Sa), respectively
In some extent fuzzy modelling requires quite sufficient
knowledge about the cutting process. Experience is necessary
factor to draw correct membership functions and reliable rule
block, which describes relationships between surface roughness
and technological parameters.
5. MODEL VALIDATION
The final step in the study was validation of models.
Cutting parameters were put into both regression model and
fuzzy model. Graphical representation of data is shown in Fig.
5 where Sameasured is compared to Saregression and Safuzzy. It can be
seen that Safuzzy values are closer to Sameasured than Saregression. It
means that fuzzy prediction model is closer to the real values
and more reliable in prediction surface roughness according to
the technological parameters.
Accuracy of each model was calculated. Regression model
proved capable of predicting the profile roughness (Ra) with
about 90% accuracy. After calculations accuracy of regression
model was about 85%, but accuracy of Fuzzy model was about
95%.
1,6
1,4
1,2
1
0,8 Sa measured
Sa
0,6 Sa fuzzy
0,4 Sa regression
0,2
0
1 2 3 4 5 6 7 8 9 10 11 12
Experiment No.
Fig. 5. Regression model and Fuzzy model validation diagram
6. CONCLUSION
Study showed that it is possible to predict surface
roughness according to technological parameters. Both
regression and fuzzy models were built.
Although fuzzy model is a bit complicated to develop than
regression model (need of experience and knowledge), it
showed more reliable accuracy than regression model
regression model 85% and fuzzy model 95%.
Further research could be done in implementing prediction
models, especially fuzzy models, into adaptive control systems
of CNC. Additionally, Fuzzy model learning capability could
be improved by implementing neural networks.
7. REFERENCES
Feng C. X. & Wang X. F. (2002). Surface Roughness
Predictive Modeling: Neural Networks versus Regression.
IIETransactions on Design and Manufacturing. 42 p.
Lou M. S.; Chen J. C. & Li C. M. (1998). Surface Roughness
Prediction technique For CNC End-Milling. Journal of
Industrial Technology. Vol. 15, No. 1 (November 1998), 1-
6.
Tomomitsu N. (1997). Device and corresponding method for
determining a fuzzy logic conclusion based on a plurality of
machining rules, USPTO, US 5598512, USA
Zadeh L. A. (1965). Fuzzy Sets. Information And Control. Vol.
8, 338-353.
*** (2001) fuzzyTECH 5.5 User’s Manual, INFORM GmbH,
pg.102