Title: Assessment of machining with uncoated and coated end mills and determining surface topography using 2D fast Fourier transform

Authors: M.N. Durakbasa; P. Demircioglu; I. Bogrekci; G. Bas; A. Gunay

Addresses: Department of Interchangeable Manufacturing and Industrial Metrology, Institute of Production Engineering and Laser Technology, Vienna University of Technology (TU-Wien), Karlsplatz. 13/3113, 1040 Vienna, Austria ' Department of Mechanical Engineering Faculty of Engineering, Adnan Menderes University, 09010, Aydin, Turkey ' Department of Mechanical Engineering Faculty of Engineering, Adnan Menderes University, 09010, Aydin, Turkey ' Department of Interchangeable Manufacturing and Industrial Metrology, Institute of Production Engineering and Laser Technology, Vienna University of Technology (TU-Wien), Karlsplatz. 13/3113, 1040 Vienna, Austria ' Department of Mechanical Engineering, Faculty of Mechanical Engineering, Yildiz Technical University, 34010, Istanbul, Turkey

Abstract: This study focuses on establishing a methodology for the surface roughness characterisation of uncoated and nano multilayer coated tools deposited by physical vapour deposition (PVD) managing an evaluation process after comparison of both experimental measurements utilising the stylus profilometer and the digital microscope, and also image processing technique, fast Fourier transform (FFT). The results showed that the surface roughness of coated cutting tool stayed reasonably constant while those of uncoated cutting tool changed drastically. Cutting edge of uncoated cutting tool was worn out during machining (about 2 mm width and 0.5 mm depth) while that of coated cutting tool remained its original shape almost the same after 25 min. The results from image processing agreed with those from roughness measurement technique. It can be concluded that micro/nano scale measurement techniques combined with image processing technique establish an improved evaluation methodology for the surface of the high precision milling tools.

Keywords: uncoated end mills; coated end mills; nanocoating; surface topography; surface roughness; nanometrology; fast Fourier transform; FFT; nanomanufacturing; nanotechnology; surface quality; physical vapour deposition; PVD; image processing; high precision milling.

DOI: 10.1504/IJNM.2012.051108

International Journal of Nanomanufacturing, 2012 Vol.8 No.5/6, pp.493 - 507

Received: 20 Dec 2011
Accepted: 06 Aug 2012
Published online: 21 Aug 2014 *

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