Surface Roughness Analysis Using Sound Signal in Turning of Mild Steel and Their Comparison in Normal and Hot Condition

Abstract

Among every other parameters of production process, surface roughness holds its ground as one of the most crucial factor for quality analysis. Good surface finish is a major criterion in almost every machining process. If the surfaces aren't smooth, many kinds of mechanical, thermal, frictional, vibrational problems may occur. So minimizing surface roughness should be top priority. Surface roughness depends on many factors. But it has a direct relation with the tool conditions and overhang length of the tool. With the variations of tool conditions and overhang length the machining sound level also varies. In this present work, an analysis has been made based on captured sound signal to correlate the surface roughness parameters with sound level at different tool and overhang length conditions. As the cutting tool wears out due to continuous usage, surface roughness also develops on the tool surface. It has been observed that with the increase of overhang length the sound generated level within the cutting zone varied and surface roughness in the job also varied due to the effect of vibration and friction. A correlation factor has been investigated with the sound level variation to analyze the surface roughness condition with different tool wear and overhang length.