SURFACE ROUGHNESS MODEL OF TURNING PROCESS FOR ST 37

Eko Prasetyo
Mechanical Engineering Department University of Pancasila Jakarta, Indonesia e_prasetyo73@yahoo.com

Wina Libyawati & Agri Suwandi

Mechanical Engineering Department University of Pancasila Jakarta, Indonesia

AbstractSurface roughness plays an important role in determining and evaluating the quality of machining result applied on a product. Surface roughness level influenced by several machining parameter include object and tool characteristic, the desire final form of surface, or treated as surface integrity (combination among or all of temperature, stress, and deformation possibility during machining), vibration, and chatter. Turning is types of machining process that can produce cylindrical shape with high precision. Industry has many standards concerning surface roughness among that are ISO R1302 and DIN 4678, studied by Bimbing et al. about the uncertainty value during testing to obtain surface roughness based on several machining parameters but neglecting correlation among parameter. Kumar et al. developed statistic model for surface roughness based on several turning parameters but not yet included cooling process and vibration aspect. Hence to those an opportunity open to make prediction model for surface roughness conclude vibration by using experiment data for certain machining process and material. The researcher made regression model based on several turning parameters with MathCAD aid. The output of this research is a model to predict surface roughness value with several turning parameters as the input. Keywords-surface parameter;model roughness;turning; correlation among

smoothen manufacturing process. The correlation between parameter and surface roughness depicted by Surface Integrity. Surface integrity is a surface characteristic description based on topology (geometry), physical appearance, chemical and mechanical properties, and metallographic. Analysis and modeling for surface roughness had been conducted by many researchers by weighing influence each or correlation among parameter toward surface roughness value. Bimbing et al[2] has make a research about the influence of measurement parameter to obtain surface roughness value toward the uncertainty value for each measurement based on ISO R1302 with flange yoke surface as the case study. Flange yoke is a component in vehicle transmission device. The result of this research is uncertainty value from measurement data of surface roughness can be an indication on how successful a turning process can be. Yet this research didnt consider correlation among turning parameter. Ibraheem[3] has made a prediction model for surface roughness value by using SPSS Regression based on length, diameter, and final length of the work piece. The model is presented as follow: Ra = 6,311*10-2 + 6,91*10-6L 1,13*10-3D + 6,08*10-5l 3,76*10-6 Ll + 1,12*10-7 DLl Where Ra is predicted surface roughness, L is the work piece length, D is the work piece diameter, l is the work piece length after turning process. The result of this research shown 4,6% deviation between predicted value and measurement data for surface roughness. The deviation proof SPSS capable to make a predicted surface roughness model based on 3 turning parameter combination. This model can be employed by any types of machining process because that only considered main parameter in machining in term of geometry. Thamma[4] has conducted comparison between surface roughness model which used depth cut as the key variable and the ones with depth cut as ordinary variable. Data processing to obtain the model is conducted with the help of Minitab version 14 and Microsoft Excel. Surface model which used depth cut as the key variable is: Ra1 = 39,5 -0,0272V -9964 Fr + 33,9 D - 429 Nr + 0,0044 VD + 7,08 VFr + 0,325 VNr - 1496 DFr -767 DNr + 113989 Fr

I. INTRODUCTION Surface roughness plays an important role in determining and evaluating the quality of machining result applied on a product. Surface roughness has a unique characteristic in comparison to material characteristic because it is a result from machining process. Surface roughness explained as arithmetic value symbolized by Ra, based on measurement process on several spots on the object. Generally turning is a machining process which employed single cutting tool to produce cylindrical shape with high precision surface roughness. Kalpakjian[1] had summarized main parameter on turning process, which are cutting speed, length, initial and final diameter of the object, depth cut, time, torque, power, Material Removal Rate (MRR). Even though many parameter influence turning process, but not all of it can be the main parameter because only several parameter can be controlled and easy to be measured. Correlation among main parameter must be indentified to

Nr 4,34 VDFr + 0,127 VDNr 83,8 VFr Nr + 119194 DFr Nr Where Ra1 is measurement result of surface roughness value, Fr is feed rate, V is cutting speed, D is depth cut, Nr is radius nose, and K is constantan. While the surface model which used depth cut as ordinary variable is: Ra2 = 44,6 -0,296V - 11055 Fr 452,20 Nr + 0,0204 VD + 7,582 VFr + 0,327 VNr + 5777 DFr - 614 DNr + 118279 Fr Nr 7,71 VDFr + 0,111 VDNr 83,8 VFr Nr + 90594 DFr Nr Both model shown deviation value 0,357 with the accuracy level 99.3%, hence to that both applicable to predict surface roughness value based on 4 turning parameters combination which are feed rate, cutting speed, depth cut, and radius nose. This model can developed by adding several parameters related to properties of tool and work piece. But this model didnt consider the existing industrial standard. Kumar et al[5] make a regression model with the aid of Matlab to determine surface roughness value. The model was a correlation impact between feed rate, depth cut, hardness for material and tool, material and tool temperature toward surface roughness. Each parameter data is taken from three different materials with also three different diameters. The statistic model was: Y = A + b X1 + c X2 + d X3 + e X4 + f X5 + g X6 With Y is surface roughness, X1 until X6 in accordance are cutting speed, feed rate, depth of cut, tool hardness, temperature, cutting fluid, and work piece hardness. This experiment for this model is supported by multiple regression method with a deviation less than 5 % from the real value of surface roughness. From those research above, a conclusion can be withdrawn that surface roughness model as a result of correlation among almost turning parameter had been done, except for vibration and cooling process parameter during turning process. A research about the affect of measurement process toward surface roughness value based on the uncertainty value, also already done. The previous research use software as an aid to conduct statistical calculation. Based on that researcher developed previous model by adding vibration parameter and see the interconnection with other parameter, with the aid from MathCAD. II. FACTORS INFLUENCING SURFACE ROUGHNESS

cutting process efficiency. While turning process applied low cutting speed then it will reduce the productivity of cutting process and increasing manufacturing cost. Despite the pros and cons above, too high cutting speed will resulted over heat on tool and built up cutting edge on the tool. Though cutting speed during turning process can be controlled yet it can be influenced by properties of toll and work piece, and types of cooling fluid.. B. Feed Rate Feed rate is an allowable distance for the tool toward the work piece in term of one cycle (revolution) from the spindle headstock. Feed rate can be described as linear movement per revolution of spindle headstock. During turning process the chuck and tool are moving along the bed to cut the material gradually until reaching the desired dimension. C. Depth of Cut Depth of cut based on many researches and references is the ultimate parameter in turning process and give major impact toward tool life cycle and cutting force. Depth cut will give major impact toward the surface roughness level if the tool applied for turning process too small. Combination between low depth of cut and high cutting speed will resulted low surface roughness value because existence of built edge chip. So to see the influence in a model, one must pair it with other turning parameter. D. Hardness Hardness value for work piece and tool influence surface roughness because during turning process there will always be friction between work piece and tool. The friction later on will trigger heat and affect the slicing form on the work piece and at the same time will transform nose radius shape. If those symptoms continue then it will seriously affecting surface roughness level. E. Vibration Vibration during machining process can be in the form of un-natural vibration , which is vibration from the outside. Other causes are defect on machine components in turning position, vibration from supported component like machine base or leg, friction between tool and work piece, vibration due to uncontinuous cutting process and other. The vibration happened in lathes is included initial vibration when the machine ignited and working vibration during the turning process. Vibration can happen in lathes whether it operates on high, medium, or low cutting speed. Generally significant vibration on lathes machine located on the base, in-contact surface (such as tool, chuck, gear box), and body of machine because directly connected to work piece.

Surface roughness value for turning process is influeced by many factors either in combination or simply stand by it self, among those are: A. Cutting Speed Cutting speed in turning process can be defined as a value in meter per minute unit when the work piece surface is passing thru a tool during machining process. Turning process with high cutting speed will influenced tool life time and

4 3

TABLE II.
1 5
Depth of Feed rate cut(X1) (X2)
0.3 0.3 0.3 0.3 1 1 1 1 1.5 1.5 1.5 1.5 10 20 30 40 10 20 30 40 10 20 30 40

MACHINING PARAMETERS DATA VS RA

Hardness material (HRB)(X3) 88 98 99.5 90 97 89 90 97 100 87 98 97

Average Hardness tool Vibration (HRC)(X4) (X5) 63.5 63 62.5 63 63.5 63.8 63 63 62.8 63.5 63.5 63.8 8.40 2.23 1.86 2.34 4.60 7.37 4.50 2.97 6.70 8.83 4.43 5.43

Ra (Measurement result) (Y)

3.53 1.52 0.73 0.72 6.43 2.33 2.18 0.84 9.13 4.32 3.36 6.30

1 = tool; 2 = chuck; 3 = gear box ; 4 = head; 5 = body Figure 1. Several Vibration Location Points in Lathe machine (Adopted from: Singh[6])

III. MODEL The purpose of this linear regression model is to see the dependency level of surface roughness toward 5 (five) combination of turning parameters, which are depth of cut, feed rate, hardness for material and tool, and vibration, in order to predict the surface roughness value before the turning process executed. The statistical model is as follow: Y = A + b X1 + c X2 + d X3 + e X4 + f X5 Where Y = surface roughness and X1 until X5 in series are depth of cut, feed rate, hardness for material/work piece, hardness for tool, and the average vibration from the machine, chuck, gear box and tool. The dependency level is tested by using standard deviation and t-test to ensure the validity of the model. The model is based on 12 (twelve) testing data during turning ST 37 material by using lathe machine type YAMCL40100G, with the hardness tester type SURFTEST SJ201 P/M, and vibration meter 8201 AH. The tool is using HSS TYPE Bohler MO rapid extra 1200 with right hand tip. The vibration data is presented separately from the depth cut until hardness for ease references on Table 1. While Table 2, presented variable X1, X2, X3, and X4. The data taken based turning process on work piece dimension with the diameter 22 mm and length 230 mm
TABLE I.
Rotation Engine Parameter 330 330 330 330 675 675 675 675 1200 1200 1200 1200

The experiment is being conducted based the following step, which summarized on Fig.2: 1. Preparation Preparation is a step to determine the objective and the goal of this research based on study literature. Setting process for lathe machine and tester for hardness, vibration and surface roughness took in to account during this step. 2. Testing The testing is divided in to two branches which are: - Testing to obtain turning parameters The purpose of this test is to obtain turning parameter when producing a work piece with the same dimension and material. Vibration data is measured based on 3(three) variation of rotation engine parameter on seven different spots. Combination between Depth of cut and feed rate also set in to 3(three) variation of depth of cut. - Surface roughness testing Surftest 21 SJ tested the material both for tool and material to obtain the empirical Ra value. 3. Statistical Modeling The multiple regression method is being adopted to form a statistical model based on the correlation between turning parameter toward empirical surface roughness value. Since turning parameter is consist around 100 parameters, hence to that this research only assign Depth of cut, feed rate, hardness of material and tool, and vibration as independent variable. The dependent variable is empirical surface roughness. 4. Analysis and Implementation The stage aimed to test the statistical model by using t-test based on the discrepancy between predicted and empirical surface roughness value. If this model can fulfill the prerequisite t-test value then it consider applicable to predict surface roughness value for turning process.

VIBRATION D ATA BASED ON ROTATION ENGINE PARAMETER

Vibration (Left Head Stock) 8.40 2.6 Vibration (Right Head Stock) 8.40 2.6 2.6 4.6 8.6 6.3 6.7 10.3 6.2 Vibration (Middle Head Stock) 8.40 2.6 2.6 4.1 4.6 8.6 6.3 5.2 6.7 10.3 6.2 9.5 Vibration Vibration Vibration (Inner Tool (gear box) (Tool) Post) 8.40 8.4 2.6 2.6 4.1 4.6 8.6 6.3 5.2 6.7 10.3 6.2 9.5 8.4 2.6 2.6 4.1 4.6 8.6 6.3 5.2 6.7 10.3 6.2 9.5 Vibration (Overall) 8.4 2.6 2.6 4.1 4.6 8.6 6.3 5.2 6.7 10.3 6.2 9.5

4.6 8.6

4.6

6.7 10.3

6.7

V. CONCLUSION The multiple regression model to predict surface roughness value based on depth of cut, feed rate, hardness for work piece, hardness for tool and vibration by using least square method prove that surface roughness is highly dependent on to depth cut and vibration parameter. Depth of cut in combination with hardness influence surface roughness due to friction between both during turning process. Friction caused heat. The surface roughness value increases in line with heat. The correlation between depth of cut and vibration in the model shown surface roughness value increase in line with the increment of depth cut and vibration. That happed because the deepest depth of cut double up vibration affect on to tool aside from machine. This model can be developed by linking all turning parameter and considering accuracy level during measurement which include human aspect.

REFERENCES
[1] [2] Kalpakjian, Serope dan Schmid Seven. (2006), Manufacturing Engineering and Technology, Edisi ke Lima, Prentice Hall. Bimbing, Atedi dan Djoko Agustono. (2005), Standar Kekasaran Permukaan Bidang Pada Flange Yoke Menurut ISO R 1302 dan DIN 4768 dengan Memperhatikan Nilai Ketidakpastiannya, Media Mesin Volume 6 No.2 Juli. Ibraheem, Abbass F. (2008), Prediction of Surface Roughness In Turning By Multiple Regression Model, Eng.&Tech. Vol. 26, No.9. Thamma, Ravindra. (2008), Comparasion Between Multiple Regression Models to Study Effect of Turning Parameters on the Surface Roughness, Proceedings of The 2008 IAJC-IJME International Conference. Kumar Atul, Sudhir, dan Garg R.(2011), Statistical Modeling of Surface Roughness in Turning Process, Singh Rajender (2006), Introduction to Basic Manufacturing Processes and Workshop Technology, New Age International (P) Limited, India. Montgomery, Douglas C, (2005), Design and Analysis of Experiments, Edisi 6, John Wiley & Sons Inc. Harinaldi (2005), Prinsip-Prinsip Statistik Untuk Teknik dan Sains, Erlangga

[3] [4] Figure 2 Methodology [5]

IV.

EXPERIMENT RESULT

[6] [7] [8]

By applying least square method on the data and matched up with the model with the aid of MathCAD, the researcher get: Y = -45.58 + 1,53 X1 0.06 X2 + 0.29 X3 + 0.29 X4 +0.58 X5 With a limit of error set out on -2.201 < ttest < +2.201[8]. Afterward we obtain standard deviation 1.30 and ttest = -0.56.