Surface Roughness Measurements Research Articles

Effect of different polishing systems on surface roughness and gloss values of single-shade resin composites.

The aim of this study was to evaluate variations in the surface roughness and gloss of different single-shade resin composites after polishing with a range of systems. In total, 120 specimens were prepared from three different types of single-shade resin composites (supra-nanospherical-Omnichroma, nanohybrid-Charisma Diamond One, and microhybrid- Essentia Universal). The specimens were placed in distilled water and stored at 37°C for 24h. Each resin composite (n = 40) was divided into four groups (n = 10) according to the finishing/polishing (F/P) system: Mylar strip (control), Sof-Lex (multi-step), Twist Dia (two-step), and OneGloss (one-step). Surface roughness and gloss were measured. Surface characteristics were evaluated by atomic force microscopy (AFM) and a scanning electron microscope (SEM). A two-way analysis of variance (ANOVA) and Tukey's honestly significant difference test were used for statistical analysis (p < 0.05). Among all the composites, both the highest surface roughness and lowest gloss values were obtained in the groups treated with the OneGloss polishing system (p < 0.05). Compared with all the composites, Omnichroma had the lowest surface roughness and highest gloss values (except Twist Dia) both unpolished and after polishing with all the F/P systems (p < 0.05). All composites treated with the Twist Dia F/P system had similar gloss values. The results of the AFM and SEM analyses were consistent with the surface roughness measurements. The gloss values of both the microhybrid and nanohybrid composites after F/P using the two-step system was superior to that of the traditional multistep system. The surface of the supra-nanofilled resin-based composite was smoother than that of both the microhybrid and nanohybrid composites.

Mechanical and surface characterisation of additively manufactured polyetheretherketone for the tribo test

Purpose The additive manufacturing process, such as fused filament fabrication based on material extrusion, fabricates the samples layer-by-layer. The various parameters in the process significantly affect the dimensions, structure and mechanical properties of the fabricated parts. The purpose of this paper is to investigate the surface and mechanical properties that can affect the contact characteristics with other materials during tribological tests. Design/methodology/approach The investigation of 3D-printed Polyetheretherketone (PEEK) includes the measurement of dimensions, microhardness, surface roughness, surface energy and tensile strength to define material characteristics. The crystallinity is measured using an X-ray diffractometer to understand the hardness behaviour. Findings The printing parameters affect its surface roughness, hardness and crystallinity. This change in parameters such as layer thickness and infill density impacts mechanical properties such as hardness and surface roughness, which will influence the contact mechanism with the counter body during any tribological test. The change in a single parameter during the sample fabrication and the change in the surface and mechanical properties are observed. Research limitations/implications The material cost plays an important role in conducting numerous destructive tests, which is a major limitation to conducting parameter optimisation by varying more parameters. The study is limited to the as-fabricated samples rather than finished samples and without any heat treatment. Achieving optimal parameters is integral to the success of additive manufacturing, ensuring the production of components with consistent performance. Practical implications The study aims at the application of 3D-printed PEEK for bush or journal bearings that can be directly used in practice. The mechanical properties discussed in this paper can fill the gap between theory and practice. Social implications The research provides all fundamental properties, including the printing parameters and their effect on the dimensions and surface structure, which are required to understand the material and its use. The results are consistent as at least four samples were tested for tribological behaviour. The conclusion is updated as per suggestions. Originality/value The study outlines the relationship between the change in layer thickness and infill density with changes in surface energy, surface roughness, hardness and tensile strength. The deformation and adhesion during the friction test depend on these properties.

Layer interface characteristics and adhesion of 3D printed cement-based materials exposed to post-printing temperature disturbance

The layer interface, which is vital for the performance and longevity of 3D printed cement-based materials (3DPCM), is very sensitive to the environmental conditions because of the lack of formwork. Nevertheless, the current limited understanding of how temperature affects the layer interface has restricted the application of 3D printing in different construction scenarios. Here, we revealed the effects of temperature on the multi-scale phase distribution features of the layer interface through mercury intrusion porosimetry, X-ray computed tomography, nanoindentation and scanning electron microscopy with energy dispersive spectroscopy techniques. Additionally, the interlayer bond strength of 3DPCM was evaluated via the splitting tensile test. Small amplitude oscillation, surface roughness and isothermal calorimetry measurements were employed for an in-depth analysis of the mechanisms. Results indicate that an increase in temperature post-printing reduces the discrepancies in aggregate volume fraction between the layer interface and bulk matrix due to the increasing structuration rate and the amount of cement paste at the interface due to the reduced settlement of aggregates. The porosity difference between the layer interface and bulk matrix decreased with increasing temperature due to the pore size refinement by faster filling with hydrates. In addition, a more concentrated distribution of atomic ratios and elastic modulus of hydrates were observed at the layer interface of 3DPCM hardened at higher temperatures. Increased curing temperature improves the interlayer bond strength of 3DPCM owing to the enhanced aggregate interlocking, reduced porosity and improved high-density CSH content.

Tribological performance of TiO2 nanoparticle-oil-water emulsion in the hot rolling process

This study aims to evaluate the lubrication performance of a nano-TiO2 oil-in-water (O/W) emulsion during the hot rolling process. A series of O/W emulsions with varying concentrations of TiO2 nanoparticles (0.05, 0.1, 0.3, and 0.5 wt.%) were synthesized. Tribological tests were conducted under a load of 70 N for 10 minutes to determine the optimal concentration based on anti-frictional properties. The O/W nano-emulsion optimized with a 0.1 wt.% concentration of TiO2 applied in the hot rolling process of IS 2062 E250 grade steel. This application resulted in a reduction of rolling force (RF) and surface roughness, suggesting its potential as an alternative lubricant. The results indicated superior antifriction performance at a TiO2 concentration of 0.1 wt.%, leading to a 15% reduction in RF. Additionally, the use of the nano-emulsion contributed to a significant reduction in oxide scale formation. Surface roughness measurements of the rolled samples revealed a 19% decrease, with a roughness value of 2.125 µm, compared to samples rolled with a nano-free O/W emulsion. These findings suggest that nano-TiO2 O/W emulsions could serve as an effective alternative to conventional O/W emulsions in future industrial metalworking applications.

Effects of various laser applications on surface roughness and bond strength to veneering composites of polyether ether ketone (PEEK) and polyether ketone ketone (PEKK) materials.

The aim of this study was to investigate the bond strength between PEEK/PEKK and composite resins after various laser treatments and to compare the effectiveness of lasers on these polymers. 130 disc-shaped PEEK and PEKK blocks were obtained (10mm diameter-4mm height). One sample from each group (10 in total) was selected for scanning electron microscopy (SEM) analysis. The samples were randomly divided into 5 different surface treatment groups for each material (PEEK and PEKK): Er: YAG laser, Nd: YAG laser, diode laser, femtosecond laser and control (no surface treatment) (n = 12). Baseline and post-treatment surface roughness measurements were performed using a profilometer. The composite resin was bonded and SBS was measured. Comparisons among the groups were conducted via Kruskal-Wallis, one-way ANOVA; Tukey and Dunn tests were used as a post hoc test (p ≤ 0.05). All lasers significantly increased the roughness values of the PEEK and PEKK samples. In terms of shear bond strength; the Er: YAG and femtosecond laser groups had the highest values and the Nd: YAG, diode and control groups had the lowest values of the PEEK samples (p ≤ 0.05). The control group had the highest bond strength values and the femtosecond group had the lowest values for PEKK samples (p ≤ 0.05). All laser treatments increased the surface roughness of the PEEK and PEKK. Lasers increased the bond strength of PEEK to the veneering composite resin and decreased the bond strength values of PEKK. This shows that lasers behave differently in PEEK and PEKK materials.

Internal surface finishing and roughness measurement: A critical review

Internal surface finishing and roughness measurement: A critical review

Characterization of micro-wire electrical discharge machining surface texture by empirical mode decomposition

Surface roughness is a critical factor for the operational efficacy and lifespan of the manufactured components, often serving as a key metric for evaluating manufacturing processes and determining acceptance of a component. Traditional surface roughness measurements are highly sensitive to the fixed standard cut-off length, influencing the scale at which surface texture features are analyzed. Thus, developing techniques with more reliable filtering of surface features is essential for accurate surface metrology. This research proposes a novel method that combines Empirical Mode Decomposition (EMD) and Fast Fourier Transform (FFT) for surface roughness characterization. We applied our method to Nitinol shape memory alloy (equal atomic proportions of nickel and titanium) surfaces processed using micro-Wire Electrical Discharge Machining (μ-WEDM). Our results demonstrate that the EMD-FFT method significantly outperforms traditional filtering, especially for surfaces without distinct patterns like μ-WEDM. This improvement is particularly valuable for materials like Nitinol, which is widely used in critical applications where precise surface roughness control is essential. By accurately assessing the effects of μ-WEDM parameters on surface roughness, the proposed method reveals that for a constant pulse on time and a constant discharge current, the variation of pulse off time is more important than servo voltage. Thus, this method can contribute to optimizing manufacturing processes and producing higher-quality components with improved performance and durability.

Effects of surface roughness on the drag coefficient of finite-span cylinders freely rolling on an inclined plane

We present an experimental investigation aimed at understanding the effects of surface roughness on the time-mean drag coefficient ( $\bar {C}_{D}$ ) of finite-span cylinders ( $\text {span/diameter} = \text {aspect ratio}$ , $0.51 \le AR \le 6.02$ ) freely rolling without slip on an inclined plane. While lubrication theory predicts an infinite drag force for ideally smooth cylinders in contact with a smooth surface, experiments yield finite drag coefficients. We propose that surface roughness introduces an effective gap ( $G_{eff}$ ) resulting in a finite drag force while allowing physical contact between the cylinder and the plane. This study combines measurements of surface roughness for both the cylinder and the plane panel to determine a total relative roughness ( $\xi$ ) that can effectively describe $G_{eff}$ at the point of contact. It is observed that the measured $\bar {C}_{D}$ increases as $\xi$ decreases, aligning with predictions of lubrication theory. Furthermore, the measured $\bar {C}_{D}$ approximately matches combined analytical and numerical predictions for a smooth cylinder and plane when the imposed gap is approximately equal to the mean peak roughness ( $R_p$ ) for rough cylinders, and one standard deviation peak roughness ( $R_{p, 1\sigma }$ ) for relatively smooth cylinders. As the time-mean Reynolds number ( $\overline {Re}$ ) increases, the influence of surface roughness on $\bar {C}_{D}$ decreases, indicating that wake drag becomes dominant at higher $\overline {Re}$ . The cylinder aspect ratio ( $AR$ ) is found to have only a minor effect on $\bar {C}_{D}$ . Flow visualisations are also conducted to identify critical flow transitions and these are compared with visualisations previously obtained numerically. Variations in $\xi$ have little effect on the cylinder wake. Instead, $AR$ was observed to have a more pronounced effect on the flow structures observed. The Strouhal number ( $St$ ) associated with the cylinder wake shedding was observed to increase with $\overline {Re}$ , while demonstrating little dependence on $AR$ .

Optimizing dry milling of stir-cast and heat-treated AZ80 magnesium alloy using multiple criteria optimization technique: an experimental study.

The primary aspects of this research are to evaluate surface roughness, cutting force, and material removal rate and optimize it with dry milling process parameters for heat-treated and stir-cast AZ80 magnesium alloy. Multiple methodologies are utilized in the research, which includes the Integration of design of experiments-response surface methodology for experimental design with the technique for order of preference by similarity to ideal solution for multi-criteria optimization. In order to evaluate the effect of process parameters on the response, the experimental design manipulates the depth of cut, feed rate, and cutting speed in a systematic manner. An evaluation of the machined surface's quality is conducted via surface roughness measurements. Likewise, insights into the forces exerted during milling can be obtained through continuous monitoring of cutting forces. The calculation of material removal rate is predicated on weight reduction. The interaction between the depth of cut and feed rate has a significant impact on the critical-to-quality characteristics of the alloy, which has contribution percentage greater than 25%. This finding validates that despite the heat-treated alloy having a similar composition to the as-cast alloy (where the closeness coefficient is 0.9843), the optimal process parameters of the former are not applicable to the latter. Nevertheless, the technique used to prepare the specimen has no bearing on the material removal rate, which is a process parameter-specific effect.

A comparative study of polishing systems on optical properties and surface roughness of additively manufactured and conventional resin based composites

This study aimed to compare polishing systems on color stability, surface roughness, and gloss of additively manufactured permanent and conventional resin composites. Totally 250 disc specimens (6 mm*2 mm) were prepared from resin-based materials [G-ænial Posterior (GP), Clearfil Majesty Esthetic (CME), SonicFill-2 (SF), Tescera (Tes), and Crowntec (CT)]. Following baseline color (ΔE00), gloss (GU), and surface roughness (Ra) measurements, the specimens were randomly divided into 5 groups (n = 10/group) according to polishing systems: Control (mylar strips); OneGloss; OneGloss + Platina Hi-Gloss; OptiDisc; and OptiDisc + Platina Hi-Gloss. Specimens were immersed in coffee for 144 h following polishing. ΔE00, GU, and Ra measurements were repeated. Atomic force microscopy images were taken in all groups. Spearman’s rho correlation coefficient, Robust ANOVA, and Bonferroni correction were used for statistical analysis. Significance level was taken as p < 0.050. Significant differences in ΔE00 values were found among resin-based materials, polishing systems, and their interactions (p < 0.001,p < 0.01, and p = 0.001). Regardless of polishing system, the lowest ΔE00 values were observed in CT, while lowest gloss (GU) values were found in Tes. The lowest surface roughness (Ra) values were detected at OptiDisc group (p < 0.001). A single type of polishing system may not be sufficient to achieve optimal results in resin-based materials.

Alternative Treatments for Zirconium Oxide to Compare Commonly Used Surface Treatments to Determine Which Has the Least Effect on the Phase Transformation.

Traditional mechanical processing of zirconium leads to an unfavorable transformation, from a metastable tetragonal phase to a monoclinic phase (t→m), which weakens the structure of the material and subsequently leads to damage to the prosthetic restoration. The aim of this research is to compare commonly used surface treatments to determine which has the least effect on t→m. Thirty cylindrical samples made of sintered zirconium were divided into six groups based on the following treatments: polishing, grinding, sandblasting, chemical etching, laser structuring or dry plasma etching. After surface treatment, the samples were subjected to the following tests: X-Ray Diffraction, microscopic examination, surface wettability and surface roughness measurements. Chemical etching, laser structuring and plasma etching significantly reduce the content of the monoclinic phase. All surface treatments significantly reduced the final amount of the monoclinic phase. However, chemical etching did not provide sufficient surface roughness. Both laser and plasma processing offer the advantage of creating structural patterns on the surface of elements. However, as plasma etching requires a mask to obtain the appropriate pattern on the surface, it seems that laser processing offers more and varied structuring possibilities. Laser structuring is easier to control and more economical than the other methods.

Effect of Material on Lathe Rotation at HSS (High Speed Steel) M42 Tool Cutting Tool Wear Level

In an era where science and technology are rapidly developing, in the era of globalization it opens a wide door for every individual to embrace change. Human resources, being the pulse that pumps industrial life, must be proficient in mastering science and technology, being able to apply it in every step of the industry, and steel has become an important milestone in various sectors, from building construction to machine components. However, behind the glitter of this civilization, technical processes such as turning the HSS M42 chisel face its own challenges. At certain rpm cycles, the tool experiences an erratic level of wear, as evidenced by the difference between the initial and final weights as well as the difference in the initial and final lengths. In the HSS M42 tool turning attempt, the HSS M42 1200 type tool with a size of 3/8x3/8x4" and a rotation speed of 700, 900, and 1200 rpm, with a cutting depth of 1 mm and a feed rate of 0.09, almost encountered a weakness. Tools that wear out quickly, especially at 900 rpm, make turning results less satisfactory. However, there was a light at the end of the hallway. In the same process, the use of HSS tools with HSS M42 1200 type, dimensions of 3/8x3/8x4", was able to answer the challenge with more promising success. At 900 rpm rotation, the wear that occurs is more controlled, resulting in a workpiece with a satisfactory level of fineness, reaching N6 in the measurement of surface roughness. As if to be a symbol of struggle, HSS chisels are able to cut finer traces in the ocean of HSS M42 chisels

Evaluation of optical and mechanical properties of crown materials produced by 3D printing.

The various advantages of crown materials produced using three-dimensional (3D) printers have increased their use in restorative and prosthetic dentistry in recent years. Accordingly, their optical and mechanical properties have become more important. To evaluate the mechanical, surface and optical properties of crown materials produced with 3D printing and computer-aided design (CAD)/computer-aided manufacturing (CAM), which has recently been used frequently in the clinic. The 3-point bending test was used to evaluate the mechanical properties of 2 different crown materials produced with 3D printing (Permanent Crown and VarseoSmile Crown Plus) and a crown material produced using CAD/CAM (Vita Enamic). After the initial color and surface roughness measurements were made, the specimens were immersed in 4 different solutions. The most translucent material was VarseoSmile Crown Plus (p < 0.05). In all specimens, coffee caused the most discoloration (p < 0.05). The effects of the solutions on the roughness were mostly observed in Permanent Crown specimens (p < 0.05). Vita Enamic showed the highest statistically significant values in terms of flexural strength (p < 0.05). The stereolithographic technique among the materials produced by 3D printing can be recommended for use in restorations due to its higher flexural strength.

Functional properties of expanded austenite generated on AISI 316L by plasma nitrocarburizing using different active screen materials

Abstract This study investigates the functional properties of the expanded austenite layers generated on AISI 316L austenitic stainless steel resulting from active screen plasma nitrocarburizing using different active screen materials, i.e. steel or solid carbon. Treatments were conducted at 460 °C for 5 hours in a nitrogen-hydrogen feed gas, whereas for the treatments using a steel active screen, methane was added as carbon precursor. Additionally, the bias plasma conditions applied at the samples were varied between 0 kW and 1.25 kW. Samples were characterized by complementary microstructural and compositional investigations, surface roughness and hardness measurements, pin-on-disk tribological tests as well as potentiodynamic polarization tests in H2SO4 and NaCl electrolytes. The functional properties of the case are discussed based on the contents of nitrogen and carbon in the expanded austenite and on their effective diffusion depths. The results show that the usage of a carbon screen generally produces surfaces with uniform layer thickness, high hardness, improved wear resistance and a delayed tendency to pitting corrosion independent of the bias condition applied to the samples. When applying both screen materials at non-biased condition, the general corrosion resistance is slightly reduced under the conditions used, however, the layers generated using the carbon screen have a wear rate that is 3 times lower. It can be concluded that the carbon screen represents a robust treatment variant for austenitic stainless steels to produce sufficiently thick and wear-resistant surface layers in a short treatment duration, which still have the potential to maintain the corrosion resistance in different environments.

Corrosion-Resistant Polymer Composite Tubes with Enhanced Thermal Conductivity for Heat Exchangers

The heat transfer surfaces of heat exchangers are usually made of metals which may suffer from severe corrosion. When corrosive fluids are present, highly corrosion-resistant metals, graphite or ceramics are used, resulting in high costs. This study presents measured data on the thermophysical and mechanical properties of recently developed corrosion-resistant polymer composite tubes for use in heat exchangers. Extruded polymer composite tubes based on polypropylene or polyphenylene sulfide filled with graphite flakes were investigated. The anisotropic thermal conductivities of the polymer composite tubes were measured at various temperatures. The through-wall thermal conductivity of the tubes made of polypropylene filled with 50 vol.% graphite is increased by a factor of 30 compared to pure polypropylene, resulting in a thermal conductivity of 6.5 W/(m K) at 25 °C. The tubes composed of polyphenylene sulfide filled with 50 vol.% graphite have a through-wall thermal conductivity of 4.5 W/(m K) at 25 °C. The mechanical properties of the polymer composites were measured using tensile and flexural tests at different temperatures. The composite materials are more rigid and keep their mechanical properties up to a higher temperature level compared to the unfilled polymers. Surface roughness measurements show the very smooth and sealed surface of the composite tubes. The results contribute to establishing the viability of using polymer composites for heat exchanger applications with corrosive fluids.

Effect of manufacturing new U-shaped electrode on die sinking EDM process performance

Traditional electrical discharge machining (EDM) electrodes have several limitations such as long machining time, low material removal rate MRR, hazard emissions and high energy consumption. To overcome these limitations, new electrodes (plane and frame U-shaped) were manufactured considering the electrode manufacturing classifications, such as electrode flushing mechanism, electrode cross-sectional area and electrode bottom machining area. Experiments were performed on a die-sinking EDM machine using copper electrodes and aluminum alloy workpieces. The results were compared with those obtained using the conventional electrode. The newly manufactured electrodes significantly improved the EDM process performance, reducing the machining time by more than 50%, which implies a higher MRR. The reduced machining time also led to lower costs, emissions and energy consumption for efficient EDM processes. Additionally, surface roughness measurements were performed to compare the surface quality of the machined areas using different pulse-code generator systems and electrodes. The results showed an improvement in the machined surface quality when using the new electrodes in comparison with the conventional electrode when using a roughing pulse code generator system.

Surface roughness metrology with a raster scanning single photon LiDAR

We explore a novel, to the best of our knowledge, approach to surface roughness metrology utilizing a single pixel, raster scanning single photon counting LiDAR system. It uses a collimated laser beam in picosecond pulses to probe a surface, capturing the changes of back-scattered photons from different points on the surface into a single mode fiber, and counting them using a single photon detector. These back-scattered photons carry speckle noise produced by the rough surface, and the variation in photon counts over different illumination points across the surface becomes a good measure of its roughness. By analyzing the variation frequency as the LiDAR scans over the surface using machine learning techniques, we demonstrate general measurements of surface roughness from 1.21 (1.27±4.51) to 102.01 (87.97±10.55) microns.

Indirect measurement of bridge surface roughness using vibration responses of a two-axle moving vehicle based on physics-constrained generative adversarial network

This study addresses the challenge of indirectly measuring bridge surface roughness through the vibration responses of a moving vehicle, which is crucial for pavement maintenance and bridge safety assessment. A physics-constrained generative adversarial network (PC-GAN) was proposed for the probabilistic estimation of surface roughness. The method consists of two steps: initially, a GAN informed by physics-based knowledge extracts combined information of bridge vibration deflection and surface roughness from vehicle accelerations. Subsequently, a feed-forward network isolates the bridge surface roughness from the combined data. Numerical examples validate the PC-GAN method, demonstrating sustained high accuracy under challenging conditions, including ISO 8608 level C road roughness, vehicle speeds up to 8 m s-1, 10 % deviation in vehicle parameters, 10 % environmental noise, and 10 % vehicle damping ratio. Laboratory tests further confirmed the method's efficacy, with the successful detection of artificial barriers on the bridge surface and a mean relative error of 3.33 % in height estimation. The PC-GAN method is demonstrated to be a robust tool for estimating bridge surface roughness under various numerical and laboratory conditions. These findings provide valuable insights for the rapid inspection of bridge pavement conditions using vibration responses from moving test vehicles.

Characterization of surface integrity of 7075-T6 aluminum alloy subjected to microbiologically induced corrosion during high-speed machining

Microbiologically Influenced Corrosion (MIC) is one of the primary causes of corrosion damage and equipment failure in industrial environments. This paper aims to investigate the impact of microbiologically influenced corrosion on the surface integrity of 7075-T6 aluminum alloy. Through experiments involving cryogenic treatment and machining, the study systematically compares the effects of different microbiologically influenced corrosion environments on 7075-T6 aluminum alloy. Techniques such as X-ray Diffraction (XRD), surface roughness measurement, Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and work hardening were used to elucidate the influence of natural seawater (Planktonic microorganisms, PM) and marine sediment (Benthic microorganisms, BM) corrosion on the surface integrity of 7075-T6 aluminum alloy.The results indicate that, compared to PM corrosion, BM corrosion results in a smaller surface roughness of 7075-T6 aluminum alloy. Specifically, the BM-10d specimen exhibits the smallest roughness at 0.353 μm. XRD and EDS analyses show that the corrosion products after microbiological corrosion are primarily a mixture of Al2O3, AlO(OH), and Al(OH)3. The peak intensity of AlO(OH) in the (200) crystal plane of the BM-5d corrosion product is notably higher than that of the 7075-T6 aluminum alloy under other conditions. In the PM environment, the corrosion products fully cover the entire surface of the workpiece and are accompanied by significant cracking. In contrast, in the BM environment, the corrosion products mainly exhibit a granular structure, are scattered across the workpiece surface, and the exposed substrate can be observed.The microhardness of the aluminum alloy after microbiological corrosion shows a trend of increasing initially, then decreasing, and finally stabilizing. The maximum depth of the hardened layer for PM-10d is 120 μm, with a maximum hardness of 178.74 HV. Compared to PM corrosion, BM corrosion results in a significantly greater hardened layer depth for 7075-T6 aluminum alloy, with the BM-10d hardened layer depth reaching approximately 140 μm and the peak hardness at 185.36 HV. Additionally, in the BM environment, the precipitates are fewer compared to those in the PM environment and exhibit a non-continuous, non-grain-boundary precipitation band.

THE INFLUENCE OF THE CUTTING PARAMETERS ON THE SURFACE ROUGHNESS AND VIBRATION SIGNAL IN THE TURNING PROCESS

The performance of the final part of the turning process, a topic of practical importance, heavily depends on the cutting parameters. Surface quality, a crucial product attribute in manufacturing, often tops consumer demands during machining due to its significant influence on product functionality. This paper assesses the correlation between the detected vibration signal, statistical parameters (Crest, Kurtosis and I-kaz3D coefficient) and surface roughness and provides valuable insights for practical applications. When the tool experiences vibrations during material removal, these oscillations leave a ripple effect on the surface of the workpiece. We aim to determine the impact of cutting parameters on surface roughness while turning 42CrMo4 steel using a carbide tool insert. Cutting parameters, such as spindle speed, feed, and depth of cut, were used. Signal processing is carried out using different techniques to identify the effect of the cutting parameters on vibration signals. Finally, we delve into the interaction effects between the cutting parameters, vibration signals and surface roughness, offering a comprehensive understanding of real-world manufacturing scenarios. Higher I-kaz3D coefficients correspond to higher surface roughness values. The I-kaz3D coefficient decreases as the surface roughness measurements decrease, indicating that the I-kaz3D technique can accurately indicate an increase or decrease in surface roughness. On the other hand, the cutting force Fc was the component most strongly correlated with surface roughness (Ra), yielding the best results across all indices (adjusted R²adj = 95.1%, er=.8 ± 2.3%).