Evaluation of the Feasibility of the Prediction of the Surface Morphologiesof AWJ-Milled Pockets by Statistical Methods Based on Multiple Roughness Indicators

Abstract

Improvement of the surface quality of machined parts is essential in order to avoid excessive and costly post-processing. Although non-conventional processes can efficiently carry out the machining of difficult-to-cut materials with high productivity, they may also, for various reasons, be related to increased surface roughness. In order to optimize the surface quality of generated surfaces in a reliable way, surface profiles obtained during these processes must be adequately modeled. However, given that most studies have focused on Ra or Rz indicators or are based on the assumption of a normal distribution for the profile heights, relevant models cannot accurately represent the surface characteristics that exist in a real machined surface with a high degree of accuracy. Thus, in the present study, a new modeling approach based on the use of a statistical probability distribution for the surface profile height is proposed. After six different distributions were evaluated on the basis of a three-stage procedure involving different roughness indicators pertaining to the abrasive waterjet (AWJ) milling of pockets, it was found that, although it is not possible to model the nominal values of every roughness parameter simultaneously, in several cases, it is possible to approximate the values of critical indicators such as Ra, Rz, Rsk, Rku and Rp/Rv ratio by Weibull distribution with a sufficient degree of accuracy.

Keywords

• surface roughness
• probability density function (PDF)
• AWJ pocket milling
• eco-friendly abrasive
• walnut shell