This paper describes the research results of surface quality research after the sintered carbides turning by the tools with
edges made of polycrystalline diamonds (PCD). The research trials were conducted for tools with different nose radii
and the influence of three independent parameters (vc, f, repsilon) affecting the surface roughness were analyzed. The impact of
the binder material content Co (cobalt) on the surface quality during the turning process (according to the values of
surface roughness parameter Ra) is described further on. The values of vc, f, repsilon at which the smallest surface
roughness (for the particular work piece materials) could be achieved were defined. Based on the ANOVA variance
analysis it was possible to find different effects of the research factors on the surface roughness (for the two types of
sintered carbides shafts). For the shaft with 25% Co content, the significant influence is for two parameters: the cutting
speed vc and the nose radius repsilon. For the shaft with 15% Co percentage content, the significant influence is only for the
nose radius repsilon.
This paper introduces an example of automated intelligent system for super hard materials turning process that works
according to a designed algorithm. Main task of the proposed system is to supervise the super hard materials turning
process (acronym: ISSSHMT - Intelligent Supervision System of Super Hard Materials Turning) with the maximal metal
removal rate Qvmax, the amplitude of natural tool wear and the measurement of values that define the state of the turning
process (e.g. magnitude of cutting force, surface quality, temperature in workspace). Based on the measured values it is
possible to select the optimal machining parameters (vc, ap, f), for which desired surface quality and dimensional
precision can be achieved for the maximal metal removal rate Qvmax. Presented system (ISSSHMT) can be used for any
CNC machine – accommodation for workspace and construction of the machine. An example of NC-code program that
allows using the data acquired from the ISSSHMT system by a CNC machine control unit is presented. Optimization of
the process and cost cutting can be achieved with the usage of proper target functions, for products machined with
required precision class.
The analysis results of machining accuracy after the free form surface milling simulations (based on machining EN AW-
7075 alloys) for different machining strategies (Level Z, Radial, Square, Circular) are presented in the work. Particular
milling simulations were performed using CAD/CAM Esprit software. The accuracy of obtained allowance is defined as
a difference between the theoretical surface of work piece element (the surface designed in CAD software) and the
machined surface after a milling simulation. The difference between two surfaces describes a value of roughness, which
is as the result of tool shape mapping on the machined surface. Accuracy of the left allowance notifies in direct way a
surface quality after the finish machining. Described methodology of usage CAD/CAM software can to let improve a
time design of machining process for a free form surface milling by a 5-axis CNC milling machine with omitting to
perform the item on a milling machine in order to measure the machining accuracy for the selected strategies and cutting
data.
The results of laser cutting speed influence on the quality of machined surface, defined by the Ra roughness parameter
and the shape errors, in case of machining two types of steel: i) P265GH, ii) 1.4307 are presented in the paper. Two CO2
laser cutters with maximum power of the laser beam 4000W and 3200W were used for the investigation. The
characteristics of the roughness parameter Ra depending on the laser cutting speed vc are presented. The diagrams of
shape deviation of the machined specimens for the greatest and lowest values of the Ra for the both laser cutters are also
presented. The deviation values from the theoretical profile of the particular samples, taking into account the type of the
cut-out shape profiles (circular, linear) are calculated.
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