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www.kjse.kuniv.edu.kw
Number (1) June 2004 Volume 31
KUWAIT JOURNAL OF
SCIENCE & ENGINEERING
An International Journal of Kuwait University
www.kjse.kuniv.edu.kw
KUWAIT JOURNAL OF SCIENCE AND ENGINEERING
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KUWAIT JOURNAL OF SCIENCE AND ENGINEERING
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ISSN 1024 8684
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Volume 31 - Number 1 - June 2004
- I -
INTERNATIONAL ADVISORY BOARD
Professor Saigo Megum
MATHEMATICS, FUKUOKA UNIVERSITY, JAPAN
Professor Shyam L. Kalla
MATHEMATICS, KUWAIT UNIVERSITY
Professor Rudolf Gorenoe
MATHEMATICS, FREIE UNIVERSITY, GERMANY
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BIOLOGICAL SCIENCES, KUWAIT UNIVERSITY
Professor Dirk Groenendijk
BIOLOGICAL SCIENCES, THE NETHERLAND
Professor Andrew Gilbert
CHEMISTRY, READING UNIVERSITY, U.K.
Professor K. Duckworth
EARTH & ENV. SCIENCES, UNIVERSITY OF CALGARY, CANADA
Dr. Fouad Bayoumi
CIVIL ENGINEERING, IDAHO UNIVERSITY, U.S.A.
Dr. Jamel Akbar
ARCHITECTURE, KING FAISAL UNIVERSITY, SAUDI ARABIA
Dr. Ben M. Chen
ELECTRICAL ENGINEERING, NATIONAL UNIVERSITY, SINGAPORE
Professor Farouk Badrkhan
MECHANICAL ENGINEERING, KUWAIT UNIVERSITY
- II-
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KUWAIT JOURNAL OF
SCIENCE AND ENGINEERING
VOL. 31 NO. 1, 2004
Contents
MATHEMATICS
A. PURNAMA, H.H. AL-BARWANI, M.S. AL-RAWAHI AND T.M. AL-HARTHI.
Dispersion models for brine discharges from desalination plants of Oman. . . . 1
BIOLOGICAL SCIENCES
MAJED A. ALNAQEEB, SUZANNE A. AL-BUSTAN AND NADIA Y.A. MURAD,
Eect of urban industrial expansion on the genetic biodiversity of two
desert animal species in Kuwait as determined by RAPD-PCR. . . . . . . . . . . . . . . . . . 15
ALI S. AL-OMAIR, NISAR AHEMED, ABDUL AZIZ INAYATULLAH AND
SULAIMAN AL-KANDARI, Performance in interlaboratory analytical
quality assurance studies on pesticide residues in spiked food samples . . . . . . . 33
SHABBIR A. SHAHID, SAMIRA A.S. OMAR, MUAYYAD E. JAMAL, ADEL
SHIHAB AND HANNA ABO-RIZQ, Soil survey for farm planning in northern
Kuwait.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
WASMIA AL-HOUTY, A faunistic account of beetles (Coleoptera) of the
State of Kuwait. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MOHAMMAD A.E. EL-SHEIKH AND GHANIM A. ABBADI, Biodiversity of
plant communities in the Jal-Az-Zor National Park, Kuwait . . . . . . . . . . . . . . . . . . . . . 77
HANI AL-ZALZALEH AND GHULAM SHABBIR, Eect of bioremediated soil
on growth of dierent plant species . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
J. ABDUL-SALAM, B.S. SREELATHA AND H. ASHKANANI, The eye uke
Philophthalmus hegeneri (Digenea: Philophthalmidae) in Kuwait Bay. . . . . . . . . 119
ENVIRONMENTAL AND EARTH SCIENCES
GERARD GREALISH, PETER KING, SAMIRA OMAR AND WALEED ROY,
Geographic information system and database for the soil survey for the
State of Kuwait - design and outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
J.S. AL-SULAIMI AND F.M. AL-RUWAIH, Geological, structural and
geochemical aspects of the main aquifer systems in Kuwait. . . . . . . . . . . . . . . . . . . . . . . . 149
- III -
FIRYAL BOU-RABEE AND REDA M. ABDEL-FATTAH, Seismological
observations in the State of Kuwait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
CHEMICAL ENGINEERING
MOHAMED E.E. ABASHAR, Global bifurcation analysis of two-phase
systems in continuous stirred fank reactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
MECHANICAL ENGINEERING
S.E. ORABY, A. AL-ASKARI AND E.A. AL-MESHAIEI, Quantitative and
qualitative evaluation of surface roughness-tool wear correlation in
turning operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
- IV -
Quantitative and qualitative evaluation of surface
roughness-tool wear correlation in turning operations
S.E. ORABY
*
, A. AL-ASKARI, AND E. A. AL-MESHAIEI
Department of Mechanical Production Technology, College of Technological Studies,
PAAET, P.O. Box 42325 Shuwaikh 70654, KUWAIT
*
soraby@paaet.edu.kw Tel: (+965) 9549019)
ABSTRACT
Product surface nish and its functional quality is a vital requirement and a crucial
objective of the manufacturing process. However, surface quality is a complicated
parameter to assess and, therefore, it is usually judged using comparable rather than
absolute measuring techniques.
Surface roughness in machining is inevitable since it is associated with the static and
dynamic characteristics of the dierent elements of the cutting operations: tool-machine-
workpart-cutting parameters. Moreover, it is not of a deterministic trend throughout the
dierent stages of a process since individual and overall characteristics are usually
subjected to continuous variability. Therefore, surface quality is not only dierent for
dierent products but a product quality is expected to be inhomogeneous among its
dierent zones. One of the major variability sources in machining that aect surface
roughness is the dierent inevitable modes of tool edge deformation.
In the current work, the interrelation between wear propagation and roughness
variation is extensively studied. Experimental data from longitudinal turning operation
at a wide spectrum of cutting variables are dealt with statistically so as to come up with
accurate and universal nonlinear models. Consistent correlation is found between
surface roughness variation and tool wear progress within its initial and constant
regions. However, roughness is dierently aected by wear modes either on the tool nose
or on its ank areas. Moreover, it seems that roughness variability varies as wear
progress passes from one mode to another or even moves from one domain (level) to
another. Generally, it is shown that roughness is improved as wear increases but with
possible corresponding workpart dimensional inaccuracy.
Keywords: Nonlinear regression modeling; surface roughness (nish); tool wear
and deformation; tool wear modes (nose, ank).
INTRODUCTION
The ultimate object of any machining process is to reach a pre-specied product
conguration with acceptable quality and production cost. Quality, therefore, is
Kuwait J. Sci. Eng. 31(1) pp. 219-244, 2004
one of the two pillars of the manufacturing system. Moreover, both quality and
cost are usually interrelated to each other in many manufacturing and
production aspects.
Product quality is a broad technical character covering not only product
external appearance but also its functional performance especially if the product is
one of the mating parts of a bigger useful product. Surface integrity is a common
term including information about surface roughness (nish), dimensional accuracy
and subsurface state (subsurface damage and residual stresses).
Product surface quality usually depends on many parameters involved in the
machining process. It is usually inuenced, both individually and interactively,
by the instantaneous state of any of the components of the machining
combination: workpiece-tool-machine-cutting parameters.
In turning operations, surface roughness has long been devoted to both feed
microirregularities' peaks on the machined surface and tool conguration
(Zorev 1966, Shaw 1968). However, there are some other inuential factors
aecting surface roughness such as: elastic and plastic deformation of the
surface layer, periodic formation and separation of build-up-edge (BUE),
friction between tool ank and the machined surface, lubrication conditions and
tool wear.
Roughness is improved at higher speeds as BUE disappears due to lower (less
plastic deformation) and higher strain rate. In this case, the cutting process is of
a shearing rather than a tearing (rapture) nature. As a result, cutting uid has a
limited inuence at higher speeds where it has less opportunity to reach the
cutting vicinity. Workpiece high hardness is occasionally claimed to slightly
improve surface roughness at moderate speeds but a negligible eect is noticed
at higher ranges.
Awareness should be devoted to the fact that all aforementioned factors are
themselves subjected to variability during dierent process stages, and the eect
of their nominal stationary conditions is no longer credible. It is thought that
tool wear is the main source of process variability since it excites and escalates
friction and forces (Novak & Ossbahr 1986, Oraby & Hayhurst 1991a, Oraby et
al. 1996); temperature (Takeyama & Murata 1963, Boothroyed et al. 1967,
Battacharyya & Ham 1969); consumed motor power (Martin et al. 1986); and,
even system dynamic characteristics either in the low frequency domain (Gaer
et al. 1993) or in the acoustic emission domain (Moriwaki 1980, 1983).
Eventually, the eect of the variability of all parameters is reected in the nal
topography of the machined surface. However, the success of any relevant
investigation of the process depends to a great extent on how to isolate and then
capture only the most informative data from such a complicated signature.
220 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
In this paper, the eects of dierent tool edge progressive wear modes (wear
of nose, ank, and notch) on the roughness are investigated. The eects of the
cutting parameters (Speed, Feed and depth of Cut) are considered, and the
possible nonlinearity is taken into account. Experimental data are used to
develop adequate and signicant nonlinear time-varying models.
In the next section of the paper, the principles of wear-roughness interrelation
are recalled. They are followed by a description of the experimental setup and
data collection procedures. Then, these data are used to nd an interrelation
between initial wear and surface roughness. The eect of progressive wear on
surface roughness is considered afterward and a comprehensive interrelation is
obtained. Finally the results obtained are analyzed and discussed.
PRINCIPLES OF WEAR-ROUGHNESS INTERRELATION
As shown in Fig. 1a, when longitudinal turning with a fresh tool having a nose
radius of r = 0, the height of peaks is found theoretically, R
max
, as:
R
max
=
f sin k sin k
/
sin(k k
/
)
" #
(1)
in which f is the feed per revolution, and k and k
/
are the approach and the side
approach angles respectively.
According to relation (1), the heights of surface irregularities depend only on
feed and tool congurations. However, when r > 0 (Fig. 1b), R
max
becomes:
R
max
=
f
2
8r

: (2)
Fig. 1. Roughness prole of machined surface with a fresh tool (no wear)
Equations (1) and (2) determine the nominal or, initial, surface status when
the tool is fresh since wear scars have not yet developed. This interval lasts for
221 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
only few moments after which the surface is aected by variability encountered
in all the process's responses including tool edge deformation.
Edge deformation may be either progressive or random. Progressive wear is
inevitable as the tool is in intimate contact with workpart that usually contains
abrasive inclusions. When the edge regularly wears, it continuously and
progressively looses some of its materials on both its ank and face. Edge is
categorized, according to wear mode, into nose, ank and notch regions (Fig.
2). Additionally, a crater develops on the tool face as the strain-hardened,
underside, chip surface slides out generating a crater that increases in both
depth and width as time passes. However, cratering of coated carbide inserts is
usually less likely to occur at practical moderate speed-feed ranges where the
controlling factor for tool life is the ank wear (Lim et al. 1999). Even if
cratering does exist, it doesn't directly aect surface roughness since it is
relatively far from the newly generated surface. However, some bad eects of
cratering on roughness occur at later stages of escalating wear level, when
cratering becomes so severe that it alters tool conguration especially rake
angle. Another form of tool deformation is the irregular stochastic wear modes
which are usually due to some unexpected reasons such as system instability,
misallocating (inaccurate and insecure setting) of tool or workpiece, or tool
material imperfections such as inclusions in-homogeneity and red spots.
Irregular tool deformation modes can be in dierent forms such as micro-
attrition, micro-abrasion, mechanical fatigue, thermal fatigue, edge chipping
and breakage or cracks.
In the current work only the eect of progressive edge wear on surface
roughness is investigated and other deformation modes may be dealt with in a
further study.
Fig.2. Tool wear mechanism
222 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
Despite its name, regular progressive wear (Fig. 2), is neither instantaneously
regular nor equally distributed at dierent tool contact regions, such as nose
and ank. Nevertheless, it always follows the three commonly distinguished
wear-time zones: initial wear, low-constant-wear and high wear rate regions. It
is often expedient to have dierent wear mechanisms and accordingly, dierent
impact on surface roughness is expected. This idea is supported by the fact that
each of the wear mechanisms is originated at dierent distance from the cutting
vicinity (machining point) and any variation in either magnitude or shape is
directly projected onto the mating machined surface.
EXPERIMENTAL SETUP
AND DATA COLLECTION PROCEDURES
Experimental setup and data collection procedures were a part of an integrated
project to relate dierent forms of edge deformation to system responses: forces
(Oraby & Hayhurst 1991b) and vibration and dynamic characteristics (Oraby &
Hayhurst 1991a, Gaer et al. 1993).
The aim of the current work is to nd a comprehensive interrelation between
wear and surface roughness. The Central Composite Design (CCD)
experimental design technique was used to design the experiments so as to
statistically suit the formulation procedures and, at the same time, to save time,
tools and specimens. For each of the cutting parameters (speed, feed and depth
of cut), three levels (low-medium-high) are selected for the rst order
formulation. To account for the possible non-linearity and interaction involved
in the data, two augments were added (lowest & highest). Center and augment
experiments were replicated to distinguish between lack-of-t and experimental
error. This led to 24 constant-variables as indicated in Table 1.
Multi-coated carbide inserts [Sandvik G435] were used to cut En8 hardened
and tempered alloy steel on a center lathe and measurement of wear values and
the corresponding roughness were recorded at two minute time intervals.
Parameters were selected to cover a wide range of practical cutting conditions:
speed (V) from 50 to 200 m/min, feed (f) from 0.06 to 0.6 mm/rev and depth
(d) from 1.5 to 3 mm. Each test was terminated whenever tool lifetime was
ended either by a criterion wear level or, by edge damage resulting from plastic
catastrophic deformation.
223 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
Table 1: CCD of the experimental procedures.
Test
Speed, V
(m/min)
Feed, F
(mm/rev)
Depth, D
(mm)
No. of Subtests
(Data Points/
experiment) Subtest Model Type
1
F
i
r
s
t
O
r
d
e
r
F
o
r
m
u
l
a
t
i
o
n
E
x
p
e
r
i
m
e
n
t
s
72 2 0.12 80
2 145 2 0.3 9
3 145 2.5 0.12 11
4 72 2.5 0.3 16
5
Replicates
104 2.25 0.2 16
6 104 2.25 0.2 33
7 145 2 0.12 33
8 72 2 0.3 47
9 72 2.5 0.12 53
10 145 2.5 0.3 5
11
Replicates
104 2.25 0.2 29
12 104 2.25 0.2 17
13
A
u
g
m
e
n
t
s
206 2.25 0.2 3
14 50 2.25 0.2 79
15 104 2.25 0.6 6
16 104 2.25 0.06 48
17 104 3 0.2 13
18 104 1.5 0.2 24
19
R
e
p
l
i
c
a
t
e
d
A
u
g
m
e
n
t
s
206 2.25 0.2 3
20 50 2.25 0.2 60
21 104 2.25 0.6 7
22 104 2.25 0.06 33
23 104 3 0.2 15
24 104 1.5 0.2 29
224 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
QUALITATIVE AND QUANTITATIVE
WEAR-ROUGHNESS INTERRELATION
Results shown in Figs. 3-7 reveal some general tertiary and wear-roughness
trends. Initially, surface roughness is positively aected by the wear progress to
dierent extents depending on wear rate. On reaching a wear level above 0.2
mm, surface roughness tends to be constant for some interval after which it
tends to decrease as wear increases. This matches the wear time popular trend
where it consists of three stages; initial stage, constant stage and high wear rate
plastic deformation stage at which the edge usually failed. However, trend
clarity seems to depend on the operating cutting conditions used in the relevant
experiment and, consequently, on the wear rate. In Fig. 3, where low speed and
feed are used, constant roughness level is detained until an advanced nose wear
level is reached. In contrast, when higher speed level is used (Fig. 4), surface
roughness decreases sharply at the opening of the last stage. However, even
when a high feed level is used (Fig. 5), the third stage is hardly noticed and this
may be due to the low companion speed level. Also, depth of cut seems to put its
own inuence on the trend, as shown in Figs. 4 & 6, where deeper depth is used
in the later.
In these ve cases of the CCD experiments, two observations can be obtained
from the individual analysis of each case. High interaction is involved that
prevents consistent interpretation of the data and, therefore, formulation and
modeling may lead to a global understanding of the functional practical
relationship. Additionally, it is much benecial in many practical
implementations, such as the generation of machinability data, to be used either
oine or in process advanced applications such as data banks (Almeshaiei &
Oraby 2003) and adaptive control applications (Oraby et al. 2003).
To build a comprehensive universal interrelation between wear and surface
roughness, a possible tentative structure to represent roughness variation is
proposed as:
Ra(t) = [Ra(iw); Ra(cwr); Ra(hwr)[ (3)
in which Ra(t) is the instantaneous value of surface roughness in (mm), and
Ra(iw), Ra(cwr) and Ra(hwr) are the surface roughness due to: initial wear,
constant-rate wear, and high-rate wear types respectively. This implies that at
any stage within the tool life span, the topography of the machined surface
depends upon how severely the cutting edge is deformed during its past service
time.
225 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
Fig.3. Wear - surface roughness
interrelation for test #1
Fig.4. Wear - surface roughness
interrelation for test #3
Fig.5. Wear - surface roughness
interrelation for test #4
Fig.6. Wear - surface roughness
interrelation for test #7
Fig.7. Wear - surface roughness interrelation for test #9
226 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
EFFECT OF INITIAL WEAR ON SURFACE ROUGHNESS
The rst part of relation (3) represents roughness estimates when the tool is new
and being used for the rst time. This interval lasts for few moments after which
the acute edge becomes more rounded. At this stage, roughness peaks are
theoretically aected only by level of cutting conditions:
Ra(iw) '[V; f; d[: (4)
For a quantitative assessment of the hidden trend, non-linear regression
procedures in SPSS ver10.05 (SPSS Inc.), along with experimental data
recorded at the initial stage has generated many models. The best model is
found to have the form:
Ra(iw) = 2858:364 f
(1:09567)
V
(1:113607)
d
(0=0840112)
(5)
Formulation parameters and criteria for the non-linear regression routine are
shown in Table 2. Process starts with some initial values of the parameters and
iterations continue until there is no longer any improvement in residuals
reduction. The correlation factor is computed accordingly as well as parameter
estimates, their standard errors and 95% condence interval. Also the
correlation matrix of the parameter estimates is listed in the program output.
Partial correlation of each of the cutting parameters indicates the signicance of
inclusion of both speed and feed, while depth of cut seems to have a minor eect
on model predictability.
Model goodness and signicance may be examined through some statistical
and practical criteria. To test forecasting ability, predicted values are plotted
against experimental ones as shown in Fig. 8a revealing a good agreement where
errors or, residuals, are reasonably within acceptable range. However, in order
to examine model adequacy, such errors must be randomly distributed and at
the same time, they should have no denite pattern or trend revealing nothing
against the model structure (Fig. 8b).
From technological interpretation viewpoints, parameters of model (5) reect
both the quantitative and the qualitative impact of each of the cutting
parameters on the initial value of surface roughness. For speed and feed, a
similar, but opposite, trend resulted. Regarding depth, a weak negative impact is
observed. While feed impact can be justied as bigger feed produces more
microirregularity marks on the machined surface, speed attitude may be
explained in the light of tribological aspects. At lower speeds, higher roughness
peaks are due to high friction accompanied by low strain rate (low elastic-plastic
deformation) that leads to the periodical formation and breakage of build-up-
227 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
Table 2: Typical output of SPSS execution explaining
formulation parameters and criteria
All the derivatives will be calculated numerically.
The following new variables are being created:
Name Label
PRED_ Predicted Values
RESID Residuals
Iteration Residual SS A0 A1 A2 A3
1 92728.35230 1.00000000 1.00000000 1.00000000 1.00000000
1.1 8056.918421 .535381317 .909918455 .995142797 .931378087
2 8056.918421 .535381317 .909918455 .995142797 .931378087
...................................................................................
35 9.203393644 2857.92334 -1.1135744 1.09566639 -.08400939
35.1 9.203393610 2858.32706 -1.1136049 1.09567041 -.08401011
Run stopped after 75 model evaluations and 35 derivative evaluations.
Iterations have been stopped because the relative reduction between successive
residual sums of squares is at most SSCON = 1.000E-08
Nonlinear Regression Summary Statistics Dependent Variable RA
Source DF Sum of Squares Mean Square
Regression 4 379.50861 94.87715
Residual 20 9.20339 .46017
Uncorrected Total 24 388.71200
(Corrected Total) 23 137.80533
R squared = 1 - Residual SS / Corrected SS =.93321
Asymptotic 95 %
Asymptotic Condence Interval
Parameter Estimate Std. Error Lower Upper
A0 2858.3270627 2016.4106680 -1347.831885 7064.4860107
A1 -1.113604901 .128061689 -1.380736904 -.846472898
A2 1.095670414 .078160025 .932631459 1.258709369
A3 -.084010106 .336420452 -.785770872 .6177506
Asymptotic Correlation Matrix of the Parameter Estimates
A0 A1 A2 A3
A0 1.0000 -.9142 .5790 -.4954
A1 -.9142 1.0000 -.4983 .1203
A2 .5790 -.4983 1.0000 -.1439
A3 -.4954 .1203 -.1439 1.0000
228 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
edge (BUE). When BUE prevails, it accelerates wear due to the fact that a
portion of insert material may be removed with BUE when it separates (Gu et
al. 1999). This irregular mechanism aects the edge surface leading to scratches
micro on the machined surface. Moreover, the BUE formation and removal
mechanism results in system instability through inducing an exciting force into
the system. Eventually, the tool oscillates randomly and uncontrollably
projecting its stochastic behavior on the machined surface. As speed increases,
friction is reduced and strain rate increases which is accompanied by force
decrease leading to a more stable process. After a certain limit, a further speed
increase does not inuence dynamic characteristics or mark peaks on machined
surface.
Fig.8a. Comparison between experimental and predicted values
Fig.8b. Residual magnitudes and distribution
229 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
Generally, it can be concluded that removing depth of cut doesn't aect
model predictability and at the same time simplies its use and interpretation.
Ra(iw) = 2617:86 f
(1:09318)
V
(1:109573)
with better standard error (SE) for the intercept coecient without aecting
correlation factor (R
2
=93). This implies that removing depth does not
deteriorate model goodness and its signicance and, model (6) is proved to be
both adequate and signicant enough to capture data variation and to detect the
hidden correlation in roughness-parameter experimental data. In contrast,
removing either speed or feed violates the model capability entirely.
However, statistical features and round-o errors of the model may be
further improved by scaling parameters so as to have closer amplitude domains.
Therefore, feed variability is scaled as its tenfold value (f610). Between the two
approaches, un-scaled and scaled, the latter shows better SE values especially
for the intercept parameter (Table 3).
Table 3: Comparison between scaled and natural un-scaled models
Natural-Feed Value Scaled-Feed Value (fx10)
Correlation
Factor R
2
Residuals
Sum Squares
(RSS)
T-test of Estimates
t
(SE)
Correlation
Factor R
2
Residuals
Sum Squares
(RSS)
T-test of Estimates
t
(SE)
t
bo
t
b1
t
b2
t
bo
t
b1
t
b2
93 9.234 1.67 8.94 14.5 93 9.234 1.94 8.94 14.5
An improvement in t
bo
suggests the use of the following scaled model:
Ra(iw) = 211:2356 (f 10)
(1:093178)
V
(1:109572)
Better understanding of model (7) can be obtained using both suitable three-
dimensional graphical and contouring programs such as ``Surfer'' and
``Grapher'' from Golden (Golden Software, Inc.). As shown in Figs. 9&10,
functional interrelation between each of feed and speed and surface roughness is
clearly detected. The eect of both feed and speed, along with their interaction,
is shown as a 3D representation in Fig. 9. At moderate-to-high speeds, surface
roughness follows a linear trend. However, outside this region, the relation
tends to show a non-linear attitude. This is easily noticeable by surface
contours. As shown by Fig. 10, a given response level can be attained at many
combinations of cutting parameters [V, f]. If, for any reason, one parameter
has to change, the other is selected so that Ra criteria is not violated. However,
three main regions may be identied on the graph: rst, a low feed-high speed
230 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
region where roughness Ra is in the range (1-2 mm); second, a moderate feed-
moderate speed where Ra becomes rougher reaching 10 mm. Finally, Ra reaches
its ultimate values at the high feed-low speed region.
Fig.9. Three-dimensional representation of speed-feed-roughness interrelation
Fig.10. Contours of speed-feed-roughness interrelation
231 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
EFFECT OF PROGRESSIVE WEAR ON SURFACE ROUGHNESS
Following the tool's initial wear stage, a second stage of wear-time curve starts
as wear progressively develops on the dierent cutting edge sites as explained
previously (Fig. 2). This stage usually consumes most of the tools useful lifetime
with a consistent wear rate trend that is almost linear and constant. This stage
ends with the third plastic deformation (catastrophic) stage where failure is
imminent due to tool material softening. In order to evaluate surface roughness
at the second wear stage, it is expected to be wear and time dependent as:
Ra(t) [Nw; Fw; Ncw; t[ (8)
in which Nw, Fw, and Ncw are nose, ank, notch wear respectively, while t is the
aggregate cut time.
A general form where it is aected by wear during the initial wear stage is:
Ra(t) = Ra(iw) bo Nw
b1
Fw
b2
Ncw
b3
t
b4
(9)
where (t) is the aggregated cutting time in min.
Substitutions of model (7) into (9) we get the general two-stage form:
Ra(t) = 211:2356(f 10)
(1:093178)
V
(1:10957)
bo Nw
b1
Fw
b2
Ncw
b3
t
b4
: (10)
Using non-linear estimation procedures in association with experimental data
within both initial and constant wear rate zones has led to the following
predictive form:
Ra(t) = [211:2356[(f 10)
(1:093178)
V
(1:109572)
[6:0986E[ Nw
(3:57493)
Fw
(1:61764)
Ncw
(2:8901)
t(4:3787):
(11)
Coecients values as well as other tting and statistical features are listed in
Table 4.
With high correlation factor (R
2
) and lower residuals (RSS), this model
indicates good estimation capability. The relative impact of the operating system
and wear entities are precisely detected. Each of the wear modes have a negative
correlation with roughness suggesting a very impressive trend that roughness
decreases as wear scars on the cutting edge widen. This, in association with
positive time coecient, indicates that roughness has a negative correspondence
with tool wear rate. In other words, as wear rate increases, peaks of surface
microirregularities are lowered leading to better surface nish. Also, it is shown
that among wear modes, nose wear (Nw) is the parameter that has the highest
232 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
impact on surface roughness. This agrees with the fact that tool nose
conguration, along with feed rate, is the major controlling factor to determine
the grade of surface nish. Between notch and ank modes, the former is of
higher eect (Table 4).
Table 4: Formulation statistical procedures and criteria for model 11
Nonlinear Regression Summary Statistics Dependent Variable RA
Source DF Sum of Squares Mean Square
Regression 5 11294.28035 2258.85607
Residual 605 187.61397 .31011
Uncorrected Total 610 11481.89433
(Corrected Total) 609 4020.03054
R squared = 1 - Residual SS / Corrected SS =.95333
Asymptotic 95 %
Asymptotic Condence Interval
Parameter Estimate Std. Error Lower Upper
B0 6.09863E-15 1.87021E-14 -3.06304E-14 4.28276E-14
B1 -3.574932051 .701622225 -4.952842898 -2.197021204
B2 -1.617638610 .429243930 -2.460627680 -.774649539
B3 -2.890132735 .611032660 -4.090135387 -1.690130082
B4 4.378746811 .418670422 3.556522977 5.200970645
Asymptotic Correlation Matrix of the Parameter Estimates
B0 B1 B2 B3 B4
B0 1.0000 .7166 -.0100 .4252 -.9741
B1 .7166 1.0000 -.3291 -.1201 -.7934
B2 -.0100 -.3291 1.0000 -.2422 .0875
B3 .4252 -.1201 -.2422 1.0000 -.2827
B4 -.9741 -.7934 .0875 -.2827 1.0000
However, it is observed, from the information in Table 4, that the t-test value
for (bo) is low comparing to its standard values (t 5 2). This implies that a
better model structure may still be not reached. Accordingly, it is thought that
data scaling and transformation may enhance model structure and its
robustness. Therefore, wear data were scaled and tting procedures were
repeated leading to following model:
Ra(t) = [211:2356[(f 10)
(1:093178)
V
(1:109572)
[7:38E 07[
(Nw 10)
(3:5747)
(Fw 10)
(1:6175)
(Ncw 10)
(2:8899)
t
(4:3786)
(12)
233 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
with statistical features as summarized in Table 5.
Table 5: Formulation statistical procedures and criteria for model 12
Nonlinear Regression Summary Statistics Dependent Variable RA
Source DF Sum of Squares Mean Square
Regression 5 11294.28035 2258.85607
Residual 605 187.61397 .31011
Uncorrected Total 610 11481.89433
(Corrected Total) 609 4020.03054
R squared = 1 - Residual SS / Corrected SS =.95333
Asymptotic 95%
Asymptotic Condence Interval
Parameter Estimate Std. Error Lower Upper
B0 7.38082E-07 1.03245E-06 -1.28953E-06 2.76569E-06
B1 -3.574723775 .701655101 -4.952699188 -2.196748362
B2 -1.617549321 .429233602 -2.460518108 -.774580534
B3 -2.889875050 .611068626 -4.089948335 -1.689801764
B4 4.378582893 .418706906 3.556287409 5.200878378
Asymptotic Correlation Matrix of the Parameter Estimates
B0 B1 B2 B3 B4
B0 1.0000 .7626 -.1047 .2322 -.9876
B1 .7626 1.0000 -.3291 -.1200 -.7934
B2 -.1047 -.3291 1.0000 -.2422 .0875
B3 .2322 -.1200 -.2422 1.0000 -.2827
B4 -.9876 -.7934 .0875 -.2827 1.0000
In addition to the slight improvement in t-values for almost all coecients,
model (12) converges more rapidly during tting procedures where only 80
iterations are needed compared to 274 iterations for model (11). This is an
important criterion since in some online model implementations, a high
response time is required.
Another strategy to enhance model signicance is thought to be through the
use of average wear values (Aw), as a mean of the three wear readings, in place
of individual wear values:
Ra(t) = [211:2356[(f 10)
(1:093178)
V
(1:109572)
[3:12248E = 06[(Aw 10)
(7:619195)
t
(3:96538)
234 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
with the statistical features in Table 6.
Table 6: Statistical and tting features of model (13)
Adjusted Correlation
Factor (R
2
)
Residuals Sum of
Squares (RSS)
Coecients t-test Values
b0 b1 b2
95.312 188.476 0.95 11.5 12.6
Model (13) is less complicated and results in relatively improved t-test values.
However, t
bo
is still lower than 2. Therefore, further analysis for model simplicity
and goodness has led to the use of a greater scale for average wear rate (Awr):
Ra(t) = [211:2356[(f 10)
(1:093178)
V
(1:109572)
[0:00128[(Awr 100)
(4:1761)
(14)
with the statistical features in Table 7.
Table 7: Statistical and tting features of model (14)
Adjusted Correlation
Factor (R
2
)
Residuals Sum of Squares
(RSS)
Coecients t-test Values
b0 b1
94.545 219 1.5 10.5
Model (17) shows better statistical characteristics in addition to the fact that it is
easy to manipulate without aecting the functional implementation of the
roughness-wear trend.
Individual eect of wear modes
This section is intended to extract and evaluate the individual and the independent
inuence of each wear mode on surface roughness. This gives a more precise
judgment about the impact of the variable under investigation than what is
indicated in the general models (11-13) where a possible interaction among
variables often exists. Fitting procedures have resulted in the following models:
Ra(t)
NW
= [211:2356[f 10)
(1:093178)
V
(1:109572)
[4:5397E 09[(Nw 10)
(7:4466)
t
(0:586)
;
(15)
Ra(t)
FW
= [211:2356[(f 10)
(1:093178)
V
(1:109572)
[0:0000882[(Fw 10)
(5:178)
t
(2:7411)
; and
(16)
Ra(t)
Ncw
= [211:2356[(f 10)
(1:093178)
V
(1:109572)
[4:14243E 07[(Ncw 10)
(5:969)
t
(3:986)
;
(17)
235 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
with the following statistical features in Table 8.
Or in wear rate form:
Ra(t)
NWR
= 211:2356(f 10)
(1:093178)
V
(1:109572)
0:0007316(Nwr 100)
(5:0126)
;
(18)
Ra(t)
FWR
= 211:2356(f 10)
(1:093178)
V
(1:109572)
0:002566(Fwr 100)
(3:51016)
; and
(19)
Ra(t)
NCWR
= 211:2356(f 10)
(1:093178)
V
(1:109572)
0:00127(Ncwr 100)
(3:903)
;
(20)
with the statistical features in Table 9.
Comparing normal models (15-17) and those for wear rate (18-20), the latter
give slightly better statistical characteristics regarding t-test value for (bo). In
fact, this could be a result of reducing the number of independent variables (less
degrees of freedom).
Developed models indicate that roughness Ra is negatively aected by wear
progress or by its rate. Again, nose wear proves to be the most dominant factor
on surface roughness. Notch wear mode is found to inuence surface roughness
more than ank mode does.
A better understanding of the trend of model (14) can be obtained using RSM
as indicated by Fig. 11. While Fig. 11a shows a 3D representation of wear rate
at a constant moderate speed (V=100 m/min), Fig. 11b shows a contour graph
for the same model. At a low wear rate, roughness is signicantly high and, then
dropped suddenly at a limit after which roughness is solely feed dependent. This
critical point of changing attitude is found approximately at a wear rate value of
0.012 (Fig. 11b). Beyond this critical point, roughness is greatly increased for
any increase in the feed. This low wear region usually represents the constant
wear zone while the high wear region represents the initial stage.
When the graph is intended with a given moderate feed of 0.3 mm/rev (Fig.
12), four zones, A, B, C and D, can be distinguished. Zones A and B show
elevated roughness values at wear rates lower than 0.02. While zone A exists at
low-to-moderate speeds where BUE prevails, zone B represents the higher speed
range that does not permit the formation of BUE mechanism to initiate. Other
regions, B and C, represent the trend at tool initial wear stage. Again, frequent
BUE formation and separation mechanism at low-to-moderate speeds have led
to higher roughness peaks (Zone C). These conclusions are reected in Fig. 12b
where below critical wear rate of 0.002, there are higher values of roughness.
236 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
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237 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
Fig.11a. Three-dimensional roughness-wear rate relationship at constant speed
Fig.11b. Contours representation of roughness-wear rate relationship at constant speed
238 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
Fig.12a. Three-dimensional roughness-wear rate relationship at constant feed
Fig.12b. Contours representation of roughness-wear rate relationship at constant feed
239 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
ANALYSIS AND DISCUSSION
To dierent extents and, in contrast to what was thought, a universal outcome is
noticed that tool wear propagation improves surface nish. The observed
attitude may be explained and justied in the light of process tribological and
environmental conditions.
As machining starts, the sharp edge tends to lose much of its material quickly,
randomly and discontinuously leading to higher tool oscillation amplitudes that
are reected on machined surface as high roughness peaks. Surface is further
deteriorated by the possible BUE formation and separation mechanism at lower
speeds. This lasts for few moments after which the edge is rounded reaching a
relatively stable condition when tool wear enters its second phase. Level of
roughness peaks is only cutting condition dependent. Then, wear scars on both
ank and nose starts to spread more thoroughly and regularly and, accordingly,
surface topography changes in such a way that more workpart material is left
unremoved (Fig. 13). The more ank and nose wear, the lower the roughness
peaks following the relation:
R
w
(t) = R
max
R
y
(t) (24)
in which R
w
(t) is the instantaneous peak height, R
max
is its value at zero wear
(sharp tool), and R
y
(t) is the wear value on tool nose and ank perpendicular to
feed direction. Moreover, projected microirregularities are aected by other two
factors: (i) feed alteration due to wear from (f) to (f1) (Fig. 13), and (ii) tool
oscillation especially in the radial direction. All of these factors governs the level
of surface quality as a mirror image to edge deformation especially at the nose
area normal to feed direction. This implies that less chip area is removed in that
direction when higher gross wear occurs. However, as ank wear increases,
nominal feed is aected in such a way that the width of chip cross-sectional area
increases (Fig. 13). Therefore, the net removed chip area usually depends on the
relative level of wear modes (ank and nose). In addition, another factor of tool
conguration, especially approach and inclination angles, is introduced.
Based on the obtained outcome, a simulation of machined surface
topography is shown in Fig. 14. At low wear level when the tool edge is acute,
roughness peaks are well detectable. However, as shown by Fig. 14,
microirregularities peaks are smoothened at elevated wear levels when the tool
nose attens. Simultaneously ank wear widens and hides feed marks. However,
this is usually accompanied by workpart dimensional inaccuracy where a
progressive less depth of cut is resulted so that a conical rather than a cylindrical
part shape is obtained. Smaller criterion wear level may help to avoid escalation
of such side eects so as to be within the allowable tolerance limit.
240 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
Fig.13. Roughness prole of machined surface with progressive wear
Fig.14 Simulation of surface topography as aected by wear progress
241 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
CONCLUSIONS AND FINAL REMARKS
- The current work investigated both the quantitative and the qualitative eect
of dierent tool edge progressive wear modes (nose wear - ank wear - notch
wear) on the roughness of the machined surface in longitudinal turning using
multi-coated carbide inserts to cut hardened alloy steel bars.
- Experimental data are used to develop adequate and signicant non-linear
time-varying models to relate level on instantaneous surface roughness to all
relevant controlling parameters: cutting speed, feed, depth of cut, nose wear,
ank wear and, average wear along with aggregate cut time.
- At the initial stage when the edge is acute, the inuence of speed and feed is
evident while depth of cut is found to have insignicant impact.
- Following the initial stage, roughness peaks are lowered as wear level
increases with dierent consideration to wear site and to level of operating
parameters. Wear on the edge nose is found to have the greatest impact while
wear on the edge ank has the least eect.
- The developed models in conjunction with suitable graphical and simulation
techniques, has led to the recognition of various domains of functional trends:
(i) initial wear zone with peaks depend only upon feed and speed; (ii) initial
wear zone with BUE results in higher roughness peaks; (iii) low-constant wear
rate zone with higher roughness peaks; and nally, (iv) low-constant wear rate
zone with BUE where surface quality is drastically deteriorated.
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Submitted : 31/7/2002
Revised : 19/11/2003
Accepted : 2/3/2004
243 Quantitative and qualitative evaluation of surface roughness-tool wear correlation in turning operations
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244 S.E. Oraby, A. Al-Askari, And E. A. Al-Meshaiei
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h G y v v v v v % v v v v v " v v v v v O S v v v v v v v v v ? 1974 , | v v v v v G v v v v v z v v v v v ?
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h G y A g Q * > h G y " W Q 1976 , | G z ?
G y J t ( b 1977 , I ( y + 9 J G 6 O G H
h G y v v v g v v v z v v v ( e G : F v v v A v v v } v v v 9 f v v v + v v v ? 1980 ,
G C G v v v v v z v v v v v ? G y v v v v v g v v v v v Q < v v v v v + v v v v v ? y v v v v v z v v v v v g v v v v v z v v v v v ( e
G ! v v v v v v T v v v v v v 9 ! v v v v v v + v v v v v v ? 1981 , | v v v v v v G v v v v v v z v v v v v v ?
G y v v v v v v v v v W v v v v v v v v v Q * v v v v v v v v v g v v v v v v v v v ? h G y v v v v v v v v v O Q G S v v v v v v v v v 9 J
G S v v v v v v v ; | v v v v v v v + v v v v v v v ? 1983 , G C G v v v v v v v z v v v v v v v ?
G y v v v v v v v A v v v v v v v v Q < v v v v v v v v v ( * v v v v v v v v v ? 1983 , G C G v v v v z v v v v ?
G y g Q < + ? y z g z ( e G O G Q * ? 1991 .
MA T H E MA T I C S
E N V I R O N ME N T A L A N D E A R T H S C I E N C E S
B I O L O G I C A L S C I E N C E S
C H E MI C A L E N G I N E E R I N G
ME C H A N I C A L E N G I N E E R I N G
A. PURNAMA, H. H. AL- BARWANI , M. S. AL- RAWAHI AND T. M. AL- HARTHI
Di spersi on model s for bri ne di scharges from desal i nat i on pl ant s of Oman.
MAJ ED A. ALNAQEEB, SUZANNE A. AL- BUSTAN AND NADI A Y. A. MURAD
ALI S. AL- OMAI R, NI SAR AHEMED, ABDUL AZI Z I NAYATULLAH AND SULAI MAN AL- KANDARI
SHABBIR A. SHAHID, SAMIRA A.S. OMAR, MUAYYAD E. JAMAL, ADEL SHIHAB AND HANNA ABO-RIZQ
GERARD GREALI SH, PETER KI NG, SAMI RA OMAR AND WALEED ROY
J . S. AL- SULAI MI AND F. M. AL- RUWAI H
FI RYAL BOU- RABEE AND REDA M. ABDEL- FATTAH
Effect of urban i ndust ri al expansi on on t he genet i c bi odi versi t y of t wo desert ani mal speci es i n Kuwai t as det ermi ned by
RAPD-PCR.
Performance i n i nt erl aborat ory anal yt i cal qual i t y assurance st udi es on pest i ci de resi dues i n spi ked food sampl es.
Soi l survey for farm pl anni ng i n nort hern Kuwai t .
Geographi c i nformat i on syst em and dat abase for t he soi l survey for t he St at e of Kuwai t - desi gn and out put s.
Geol ogi cal , st ruct ural and geochemi cal aspect s of t he mai n aqui fer syst ems i n Kuwai t .
Sei smol ogi cal observat i ons i n t he St at e of Kuwai t
WASMI A AL- HOUTY
MOHAMMAD A.E. EL-SHEIKH AND GHANIM A. ABBADI
HANI AL- ZALZALEH AND GHULAM SHABBI R
J. ABDUL-SALAM, B.S. SREELATHA AND H. ASHKANANI
MOHAMED E.E. ABASHAR
S. E. ORABY, AL- ASKARI AND E. A. AL- MESHAI EI
A fauni st i c account of beet l es (Col eopt era) of t he St at e of Kuwai t .
Bi odi versi t y of pl ant communi t i es i n t he Jal -Az-Zor Nat i onal Park, Kuwai t .
Effect of bioremediated soil on growth of different plant species.
The eye fluke (Digenea: ) in Kuwait Bay.
.
Gl obal bi furcat i on anal ysi s of t wo-phase syst ems i n cont i nuous st i rred fank react ors.
Quant i t at i ve and qual i t at i ve eval uat i on of surface roughness-t ool wear correl at i on i n t urni ng operat i ons.
Philophthalmus hegeneri Philophthalmidae
C o m i n g S o o n !
Editor-in-Chief Managing Editor
Professor Taher Al-Sahhaf M. Kamal Azhar
Number (1)
June 2004
Volume 31
www.kjse.kuniv.edu.kw
KUWAIT JOURNAL OF
SCIENCE & ENGINEERING
An International Journal of Kuwait University