Surface roughness prediction based on cutting parameters and tool vibrations in turning operations

In machining operation, the quality of surface finish is an important requirement for many turned workpieces. Thus, the choice of optimized cutting parameters is very important for controlling the required surface quality. The focus of the present study is to find a correlation between surface roughness and cutting vibrations in turning, and to derive mathematical models for the predicted roughness parameters based both on cutting parameters and machine tool vibrations. An FFT analyzer was used to measure tool vibrations in radial and feed directions. The surface roughness was measured using a Surtronic 3+ measuring instrument. The measured results were collected and analyzed with the aid of the commercial software packages MATLAB, BC++ and SPSS. The method could be useful in predicting roughness parameters as a function of cutting parameters and tool vibrations.